ITAtech Design Guidance For Spray Applied

Waterproofing Membranes

ITAtech Activity Group

Lining and Waterproofing

N° ISBN : 978-2-9700858-1-2 ITAtech report N°2 - APRIL 2013

 ITAtech Report n°2 – Design Guidance For Spray Applied Waterproofing Membranes – N°ISBN 978-2-9700858-1-2 : April 2013
Layout : Longrine – Avignon – France – www.longrine.fr
The International Tunnelling and Underground Space Association/Association Internationale des Tunnels et de l’Espace Souterrain (ITA/AITES) publishes this report to, in accordance with its
statutes, facilitate the exchange of information, in order: to encourage planning of the subsurface for the benefit of the public, environment and sustainable development to promote advances
in planning, design, construction, maintenance and safety of tunnels and underground space, by bringing together information thereon and by studying questions related thereto. This report
has been prepared by professionals with expertise within the actual subjects. The opinions and statements are based on sources believed to be reliable and in good faith. However, ITA/AITES
accepts no responsibility or liability whatsoever with regard to the material published in this report. This material is: information of a general nature only which is not intended to address the specific
circumstances of any particular individual or entity; not necessarily comprehensive, complete, accurate or up to date; This material is not professional or legal advice (if you need specific advice,
you should always consult a suitably qualified professional).
ITAtech Design Guidance For Spray Applied
Waterproofing Membranes

ITAtech Activity Group

Lining and Waterproofing
>> Table of contents

Author list ............................................................................................................................................................ 6

Preface..................................................................................................................................................................... 7

Background.......................................................................................................................................................... 8

Objective of the guidance document ..................................................................................................... 8

1. Why is waterproofing required? .............................................................................................................. 9

2. Introduction to spray applied waterproofing membranes ..................................................... 10

2.1. Features .......................................................................................................................................................... 10
2.2. Installation considerations ................................................................................................................... 11

3. The use of spray applied waterproofing membranes .................................................................. 12

3.1. Use of spray applied membranes to build undrained waterproofing systems
(displacement concept)................................................................................................................................................12
3.2. Systematic Drainage System ................................................................................................................... 13
3.3. Localised drainage systems.....................................................................................................................13
3.4. Mixed systems.................................................................................................................................................14
3.5. Combination with other waterproofing systems ...........................................................................14
3.6. Use of spray applied membranes to waterproof retaining walls ...........................................14

4. Typical Membrane Properties ....................................................................................................................15

4.1. System watertightness .............................................................................................................................15 ..
4.1.1. In the completed structure state ................................................................................................15
4.1.2. Dealing with water pressure during the construction phase ........................................16
4.2. Bond strength ..............................................................................................................................................16
4.3. Tensile strength, elongation and crack bridging .........................................................................17
4.4. Durability.........................................................................................................................................................17
4.5. Flammability....................................................................................................................................................17

4 ITAtech Activity Group Lining and Waterproofing

>> Table of contents

5. Trials and Testing.............................................................................................................................................17

6. Application requirements............................................................................................................................18
6.1. Management of water ingress ...............................................................................................................18
6.2. Substrate surface quality and preparation .....................................................................................19
6.3. Potential causes of local failures ......................................................................................................19

7. Quality control ................................................................................................................................................20

7.1. Coverage .........................................................................................................................................................20
7.2. Thickness .........................................................................................................................................................20
7.3. Bond to Substrate .......................................................................................................................................21
7.4. Integrity testing ...........................................................................................................................................21

8. Design aspects ...................................................................................................................................................22

8.1. Lining configurations .................................................................................................................................22
8.2. The composite shell lining system .......................................................................................................22
8.2.1. The principle of composite action ................................................................................................23
8.2.2. Improvement in performance .........................................................................................................23
8.2.3. Typical failure mode ...........................................................................................................................23
8.2.4. Waterproofing approaches.............................................................................................................23
8.2.5. Introduction to numerical modelling of CSL systems ........................................................23

Bibliography .......................................................................................................................................................24

Appendix A: Example Specification ...........................................................................................................25

Appendix A-1: Example quality control check sheet........................................................................36
Appendix A-2: Altered procedure for the watertightness test...................................................37

Appendix B: Training Certification ...........................................................................................................39

Appendix C: Generic Detail Drawings ......................................................................................................45

Appendix D: Case Studies ................................................................................................................................53

ITAtech Design Guidance For Spray Applied Waterproofing Membranes 5

>> Author list

Main Authors (in alphabetical order):

Name Company

Tom MELBYE (Chair) Normet Group

Tim BABENDERERDE Babendererde Engineers GmbH

Klaus BONIN Wacker Chemie AG

Ross DIMMOCK Normet UK

Simon GREENSTED Stirling Lloyd Polychem Ltd.

Frank GREGORY Wacker Chemie AG

Bethan HAIG Normet UK

Thomas KOTHE BASF Construction Chemicals

Europe AG

Kiril MASLEV Hydromat Ltd

Matthias REINHOLD Hagerbach Test Gallery Ltd.

Ernando SARAIVA BASF Construction Chemicals

Europe AG

Giorgio TANSINI MAPEI S.p.A.

Volker WETZIG Hagerbach Test Gallery Ltd.

Reviewers:
ITAtech AG Design

6 ITAtech Activity Group Lining and Waterproofing

>> Preface

This guidance document has been written to assist tunnel designers, contractors and owners
in understanding the benefits of and limitations in the use of spray applied waterproofing
membranes in excavated tunnels and shafts, and to provide guidance in drawing-up
specifications and design details.

Spray applied waterproofing membranes for tunnels are proprietary construction materials
that are applied to the primary lining surface with spray equipment, in order to form a coating
that is bonded to the concrete that can provide an effective barrier to the ingress of liquid
water into the structure. These materials are most commonly formulations of reactive or water-
based polymers, some of which may incorporate cement compounds, and are sprayed either
by hand or robotically. To tunnel owners, designers and contractors they can offer potentially
greater flexibility over membranes that are installed as pre-formed sheets, a waterproofing
method that has been used for many years. These spray applied waterproofing membranes
and concrete lining materials are commonly used together, and when the membrane and
lining are correctly specified and designed, may provide a fast and economic alternative
solution to preventing water ingress into tunnels.

A sprayed concrete lined tunnel typically comprises a sprayed concrete primary (often
considered and referred to as a temporary) lining, a waterproofing membrane, and a
(sprayed or cast-in-situ) concrete secondary lining (often also called the final or permanent
lining). The purpose of the primary lining is to stabilise a freshly-exposed excavation and
so prevent any rock or soil collapse. It is sprayed with concrete following excavation, using
rapid-setting concrete applied by a spraying machine controlled by a “Nozzleman”, who
directs the jet of concrete onto the substrate and can stand in a safe location some distance
away from the application surface. The primary lining also provides a firm substrate onto
which a waterproofing membrane can be applied. Using sprayed waterproofing membranes
facilitates the use of sprayed concrete for secondary linings.

ITAtech Design Guidance For Spray Applied Waterproofing Membranes 7

>> Background / Objective of the guidance document

BACKGOUND
Many tunnel owners and constructors have become accustomed to expecting leaks in
tunnels, particularly when built in wet ground or below the water table, with the issue being not
whether the tunnel will leak but by how much, and as a result whether it will be fit for purpose
throughout its design life. Excessive leakage leads to excessive costs and programme delays
during construction, and leaves the tunnel owner with maintenance costs and disruption
throughout the working life of the tunnel for which he had not planned, together potentially
with a reduced tunnel service life. Once a tunnel is leaking it is exceptionally difficult to stop
the leaks entirely.
Since the 1970’s, many sectors of the civil and structural engineering industry have been
moving increasingly towards the use of spray applied waterproofing membranes as an
effective alternative way to waterproof below-ground structures and critical infrastructures
such as cut-and-cover tunnels, immersed tube tunnels, bridges et alia.

Objective of the guidance document

This guidance document should provide designers, contractors and owners with
a comprehensive set of information that will enable the inclusion of spray-applied
waterproofing membranes for use in tunnel linings. This information is split into the following
sections:

•A
 ssessment of specific project situation and the potential benefits from the unique
properties of a spray applied membrane as the chosen waterproofing system
• Current limitations of spray applied waterproofing system
• The potential impact on the tunnel lining design; composite shell action
• Guidance on technical specifications

This guide includes an Example Specification (Appendix A), Training Certification (Appendix
B), Generic Detail Drawings (Appendix C) and Case Studies for each of the principle materials
currently available on the market (Appendix D).

8 ITAtech Activity Group Lining and Waterproofing

1 >> Why is waterproofing required?

Figure 1: Example of water ingress through a sprayed concrete lining

Robust waterproofing of underground structures is one of the most cost effective ways to enhance safety and function as well as to increase
the useful design life of new and existing structures. Special maintenance due to deterioration of the structure can be eliminated or minimised
and, more importantly, the structure is able to function for the duration of its design life.
As shown in Figure 1, water ingress through a sprayed concrete lining is possible through cracks and flaws; areas where the concrete may
have a greater permeability than the surrounding, well installed concrete. Cracks on the sprayed concrete lining are mainly located in the
vicinity of lattice girders and construction joints, e.g. in the interface top heading-bench or bench-invert, in part due to the increased likelihood
of shadowing or poorly compacted concrete in these zones. They are mostly caused by external loads, temperature changes, shrinkage, and
placement of sprayed concrete.
Watertightness is directly related to the durability and serviceability of the sprayed concrete lining. Sprayed concrete can be produced to be
watertight in small scale samples. However, building a large watertight sprayed concrete surface, as required for tunnel linings, can most
practicably be done by means of additional measures. The waterproofing system should also protect the final permanent lining against
aggressive environment (e.g. aggressive groundwater or soil).
The example specification in Appendix A includes a table characterising the watertightness classes that a project might require. In general a
client will be looking to achieve a completely dry tunnel (waterproofing class 1), but in practice a largely dry tunnel (waterproofing class 2) will
achieve their goals with a lower cost. The impact of water ingress and also any drainage and cleaning costs over the full lifetime of the project
should be considered when defining the watertightness class in the specification.

ITAtech Design Guidance For Spray Applied Waterproofing Membranes 9

2 >> Introduction to spray applied waterproofing membranes

There are different types of spray applied waterproofing membranes. shutters traditionally used for cast in-situ linings to line these complex
They may be produced by means of non-reactive systems (curing shapes and junctions. They also do not require mesh to allow the
by hydration or air-drying), or reactive systems (curing by polymer build-up of sprayed concrete on a non-rigid substrate such as with
reaction). They are all thin elements, typically with a total final thickness the use of a sheet waterproofing membrane.
of 3 or 4 mm.
A key feature of spray applied waterproofing membranes is their
Spray applied waterproofing membranes are produced and installed simple application by means of equipment often already available on
in situ against the primary tunnel lining and typically covered later on site for sprayed concrete application, thus freeing up time and space
by a secondary tunnel lining or a non-structural protective layer (e.g. for other activities. Typically 50 – 100m²/h can be manually sprayed
mortar or sprayed concrete) according to the design requirements. by 3 operators. Robotic spraying can reach application rates up to
180m²/h.
Generally the membrane can be applied in one stage directly onto
the concrete lining or substrate. Some membranes require first the Spray-applied membranes can be applied to limited sections to
application of a primer layer onto the substrate before application of provide isolated waterproofing, such as in the crown sections of
the membrane in one or two consecutive layers. tunnels, or as a continuous waterproofing system.

When installed between the primary and secondary concrete linings, Further features of spray-applied waterproofing membranes are:
spray applied membranes may bond to both primary and secondary
• Continuity without discrete joints; confinement measures
linings (double-bonding) or only to one lining (single-bonding),
(injection, tubes, weld links, compartmentalisation with
depending on the design requirements and the product chosen. In the
waterstops etc.) are not required as the bond between the
case of a spray applied membrane with double bonding properties,
membrane and the substrate prevents waterpaths developing
the resulting sandwich-structure (concrete-membrane-concrete)
between layers.
may act as a quasi-monolithic structure, depending on the bonding
characteristics and properties of the membrane. • Spray applied membranes do not have any welded seams, and
are simply connected by spraying a short overlap zone onto the
A number of tunnels, cross-passages, stations and shafts have been previously applied membrane section
successfully completed using spray applied waterproofing systems
• Easier and quicker location and repair of leaks. A seepage point
over the last years, under quite different conditions and design
through the membrane can be easily resolved locally precisely
requirements. The use of spray applied waterproofing membranes
where the seepage occurs since this point corresponds to the
is not the panacea for all waterproofing requirements for sprayed
seepage channel in the concrete behind the membrane
concrete tunnels, but it does offer a viable solution for a specific
window of ground and hydrological conditions that are quite regularly • They can be combined with other waterproofing systems.
found on tunnelling projects. Standard joint details between spray applied and sheet
membranes are available, making the system totally flexible
• They are compatible with all concrete placement techniques,
2.1. Features allowing placement of a sprayed concrete inner lining, and
reinforcement types (mesh, rebars and fibers) on either side of
Spray applied waterproofing can offer benefits in geometrically the membrane. The membrane can be sprayed straight onto
complex areas such as lay-by niches, cross passages, rail tunnel many types of penetrating items (e.g. anchored reinforcement)
turn-outs and crossover caverns, where installation of conventional • There is no folding and stretching of the spray applied
waterproofing membranes is inherently difficult and testing or locating membrane during the casting or spraying of the secondary/
of possible leaks can be challenging. permanent lining as it is in intimate contact and fully bonded to
the primary linin
Spray applied membranes lend themselves to the use of sprayed
concrete secondary linings, as they negate the need for customised

10 ITAtech Activity Group Lining and Waterproofing

2 >> Introduction to spray applied waterproofing membranes

2.2. Installation considerations Some membrane systems may require additional surface preparation,
see section 6.2.
During the application period in the tunnel, spray applied
membranes are exposed to the local environmental conditions, Spray applied membranes may not be practical to install when
such as temperature and humidity, which, depending on the chosen high levels of water ingress through the substrate are expected.
product, can interfere with the curing process of the membrane. The waterproofing system approach based on anticipated water
The membrane is also vulnerable to poor workmanship, as with all ingress through the primary sprayed concrete lining is summarised in
waterproofing systems, therefore proper training and accrediation of Figure 2 below. The chart shows water ingress ranging from
applicators is crucial for successful application. Close and systematic completely dry through to extensive water ingress throughout much
quality control of the in-situ produced membrane is required at all of the tunnel primary lining surface. Spray applied membranes are
stages of the lining construction process to ensure correct thickness deemed suitable for water ingress up to isolated areas with trickling
and coverage. or running water, or for tunnels treated with de-watering or pre-
injection methods to control water ingress to manageable levels
during construction. Tunnels that are substantially wet are ideally
waterproofed with sheet membranes for example.

What is the envisaged water ingress through

the sprayed concrete primaty lining?

Completely dry Substantially dry Capillary wetting Weak trickling water Trickling water Extensive water
some moisture patches in isolated spots over large areas ingress expected

Detail and specify appropriate water Spray membrane Design pre-construction

management systems: application unviable water control measures
• Sealing local water ingress using injection techniques
• Drain water ingress through drainage strips/pipes
• Use quick setting mortars
Sheet membrane or
water management?
Does the chosen Water
YES management
membrane require
Sheet membrane
specific substrate
treatment? Specify regulating layer
Detail regulating layer and Specify water control
substrate finish requirements requirements
NO techniques
• Ground injection
Specify geotextile • De-watering
Specify spray membrane
application requirements and sheet membrane

Figure 2: Flow chart describing waterproofing approach based on anticipated water ingress through the primary sprayed concrete lining

ITAtech Design Guidance For Spray Applied Waterproofing Membranes 11

3 >> The use of spray applied waterproofing membranes

In general the waterproofing systems of underground structures are 3.1. Use of spray applied membranes to build undrained
designed to either: waterproofing systems (displacement concept)
•W
 ithstand full water pressure, with a full round waterproofing
Typically undrained waterproofing systems are required to build
system and without groundwater drainage (displacement
underground structures in urban areas, such as metro running
concept),
tunnels and stations, where permanent drainage of groundwater
•W
 ithstand limited water pressure with a partially drained system into the tunnel may cause settlement on the surface and lead to
for partial stress relief (partial displacement concept), distress of existing buildings or facilities, but also to reduce the long
•R
 elieve full water pressure through managed drained systems, term maintenance issues associated with drainage systems and
i.e. a fully drained waterproofing system with non-pressurised pumps. Other underground structures which may require a undrained
water drainage (drained concept). waterproofing system include:
The choice of the system depends on different factors, for example, • Water transfer tunnels and shafts, incl. sewage tunnels and
the water pressure, anticipated groundwater conditions, maintenance pump storage shafts
regime, and environmental impacts (e.g. risk of settlement). • Power intake tunnels, headrace tunnels and surge shafts of
hydropower plants
• Tunnels passing through drinking water aquifers, and
• Tunnels passing below sites of scientific interest and natural
lakes, nature reserves etc.
Due to their bonding properties, spray applied membranes do not
allow water migration along the concrete-membrane interface,
reducing considerably the risk of water inflows/losses through the
tunnel concrete lining.

Figure 3: Drained system (on the left) and undrained or fully tanked
system (on the right)

Spray applied waterproofing membranes are suitable to design

and build undrained, systematically drained, locally drained, and
mixed waterproofing systems as described in the following section.
Spray applied membranes are not seen as a practicable solution for
full surface water pressure relief (fully drained) designs due to the
bonded nature of the membrane restricting the movement of water
within the system.

12 ITAtech Activity Group Lining and Waterproofing

3 >> The use of spray applied waterproofing membranes

3.2. Systematic Drainage System 3.3. Localised Drainage Systems

In this case a drained system is installed at regular intervals (e.g. This type of drained system may be used, for example, in the case of
every 5 or 10 m) along the tunnel profile to permanently avoid build- tunnel construction in an impermeable rock mass with groundwater
up of groundwater pressure behind the concrete lining. This can circulating through some cracks in the rock, and, consequently, with
be achieved, for example, with the installation of dimpled sheets localised water ingress through the tunnel primary lining.
strips onto the primary concrete lining which are connected to the
Waterproofing with a spray applied waterproofing membrane can
drainage system at the invert level. The dimpled drainage sheets
be effectively done after local seepage water has been collected
should be closely fitting to the primary concrete lining and have a
and drained, for example, by means of short drill holes, packers and
regulating layer of sprayed concrete applied prior to application of
hoses which are installed in seepage spots, or dimpled drainage strips
the waterproofing membrane.
connected to the tunnel drainage system.
Increased security against potential water pressure build up is
offered by connecting the systematic circumferential drainage
strips with longitudinal drainage strips, typically installed
in the crown and sidewalls of the underground structure.

ITAtech Design Guidance For Spray Applied Waterproofing Membranes 13

3 >> The use of spray applied waterproofing membranes

3.4. Mixed systems 3.5. Combination with other waterproofing systems

In this approach the waterproofing membrane is applied only in the Spray applied membranes can be installed in combination with other
crown of the tunnel, forming a watertight “umbrella” in the crown of waterproofing systems, i.e. plastic sheet membranes (see Generic
the tunnel. The rest of the tunnel cross section does not receive any Drawings in Appendix C). In such overlapping areas the following is
waterproofing membrane and can be considered as free draining, recommended:
allowing the groundwater to percolate along the interface between (1) Overlapping should be installed at dry areas
concrete lining and ground, or through the sidewalls, into the tunnel
(2) The surface of the substrate should be treated properly (e.g.
drainage at the invert or sidewall footing level and be drained towards
with a mortar bed) to provide a flat surface for installation of the
the tunnel portal. The span of the membrane “umbrella” normally is
sheet membrane
designed to protect the users or services installed referred to as the
“operational envelope” in the tunnel from dripping water. (3) The sheet membrane should be properly fixed. Screws and
bolts may be required depending on the existing groundwater
pressure
(4) The sheet membrane should be well stretched, and should not
present undulation or folds along its end
(5) Proper overlapping with the spray applied membrane should
be done according to supplier’s instructions (minimum width
of approx. 40 cm)
(6) Material compatibility between components should be tested
and documented.
(7) System compatibility should be provided (for example, from a
drained to undrained system). Care has to be taken to not align
structural concrete joints with waterproofing system transition
zones.

3.6. Use of spray applied membranes to waterproof

retaining walls

Spray applied membranes have also been used to waterproof

retaining walls, such as diaphragm walls, bored piled walls etc., for
example, to build metro stations. For these types of structures a
regulating layer of sprayed concrete is applied to the retaining walls,
followed by membrane application. The covering layer can either be
sprayed or cast in-place concrete.

14 ITAtech Activity Group Lining and Waterproofing

4 >> Typical membrane properties

In the following sections some typical properties of spray applied The membrane should present a minimum thickness according to the
waterproofing membranes are summarised, which in combination supplier’s instructions, in order to be watertight. Typically spray-applied
contribute to the watertightness of the lining system. The required membranes can only withstand active water pressure when they are
minimum thickness of the applied membrane influences watertightness completely cured and normally embedded between two concrete
as well as quality assurance and durability issues. linings.
As shown on Figure 4, in the case of a double bonded spray-applied
membrane (the membrane is bonded to both the primary and overlying
4.1. System watertightness
secondary lining), water has to find a path through three failure zones.
4.1.1. In the completed structure state Firstly a crack in the primary lining, then a tear in the membrane followed
by a second crack in the secondary lining. All of these failure zones
System watertightness comes from two key characteristics, the need to occur in the same spot as water cannot migrate along the
membrane watertightness and its bonding properties. membrane-concrete interface surface.
In a bonded solution, migration of groundwater along membrane- In the worst case, where defects in all the linings and membrane do
concrete interfaces cannot occur, because potential groundwater paths align, minor water ingress may migrate through this point into the tunnel.
can be eliminated, mitigating considerably the risk of water ingress However, since a point of water ingress into the tunnel must correspond
into the tunnel. Additionally, a bond between the membrane and the directly to the defect in the spray applied membrane and primary lining;
secondary (inner) lining can provide a further barrier against water it is easy to treat the source locally.
ingress into the tunnel.
Remedial measures to treat secondary lining water ingress involve the
use of standard leak sealing injection techniques, targeted at repairing
the defect in the spray applied membrane. This typically involves the
following process:
• Leak identification
• Drilling a small diameter hole (approx. 18 to 25mm) in the centre
of the source of the damp patch, to a depth that is approx. 50mm
into the primary lining
• Install packers and Inject acrylic resin to permanently seal water
ingress
• Observe water ingress and repeat injection if necessary
• Remove all packers and repair concrete surface.

Figure 4: Schematic section of final tunnel concrete lining with spray

applied waterproofing membrane between primary and secondary
lining.

ITAtech Design Guidance For Spray Applied Waterproofing Membranes 15

4 >> Typical membrane properties

4.1.2. Dealing with water pressure during the construction phase 4.2. Bond strength

Quite often during the installation of the tunnel linings, active water A distinctive feature of a spray-applied membrane is its bond strength.
pressure is present in the construction phases between the primary Membranes with sufficient bond strength provide the lining system with
lining being completed, the membrane applied and the final step of unique mechanical properties and waterproofing features that contribute
installing the secondary lining. It is vital the design also considers to the durability of the lining system.
these “temporary” stages of construction and present guidelines and The provision of sufficient bond between the primary lining and
details to manage any present water ingress. the spray applied waterproofing membrane, as per Table 2 “Spray
Current best practice is to address water ingress prior to the Applied Waterproofing Membrane Properties” in Appendix A (Example
application of the spray applied waterproofing membrane. The most Specification), shall prevent delamination of the membrane and the
common options are: consequent movement of groundwater immediately behind the
• Option 1: Fix to the primary lining a strip of dimpled drainage waterproof membrane.
sheet approximately 300 mm wide and lead water ingress The bonding characteristic of the membrane, i.e. double-bonded
to invert for temporary or permanent drainage. The dimpled or single-bonded is of fundamental importance in the lining design.
drainage strip is over coated in regulating sprayed concrete as While single-bonded membranes usually adhere only to the primary
per normal substrate preparation for spray applied membranes. (outer) lining, double-bonded ones adhere equally to both primary and
All surfaces are covered in spray applied membrane and active secondary linings.
water ingress is allowed to drain freely to drainage system in The minimum specified bond strength of spray applied membranes
tunnel. to both the primary and/or secondary concrete linings and other lining
• Option 2: Insert packers and attach drainage tubes in area components must be 0.5 MPa or greater.
of water ingress. As above option, take drainage tubes to If the primary concrete lining should be designed for permanent
temporary or permanent drainage system in tunnel invert. purposes and be integrated in the final tunnel lining, double bonded
Spray membrane to all surfaces, remove drainage tubes and membranes may be used to enable design optimisations, e.g. reduction
inject through packers to seal, or allow drainage to continue in of the thickness of the secondary lining.
permanent case through tubes.
The watertightness properties attributed to double bond properties are
• Option 3: Spray apply membranes to all surfaces other than not always facilitated by all spray applied waterproofing membranes.
the area of ingress, allow membranes to cure fully, inject water In all cases the designer must evaluate the bonding characteristics of
sealing resins in area of water ingress, and finally complete spray the chosen membrane system both to the substrate, but also to the
membrane spraying once area is sealed. overlying concrete lining. Should there be limited or no bond to the
Consideration by the designer must be given to the period of time overlying concrete the membrane will require more detailed inspection
between completing the spray applied membrane application and to ensure complete coverage, and/or methods to compartmentalise
installing the secondary lining, particularly if solutions to seal against should be considered, such as with the adoption of re-injectable tubes
active water ingress are adopted rather than allowing relief of water or hydrophilic strips at a standardised frequency along the tunnel.
pressure. In such cases where active water pressure will act on
the membrane, the installation of the spray applied waterproofing
membrane and the secondary lining should be carefully sequenced.
For solutions allowing relief of water pressure, such as temporary
drainage sheets and tubes, then the timing of the secondary lining
is less of concern. Finally, the curing characteristics of spray applied
membranes may vary from product to product and guidance should
be sought from the manufacturers.

16 ITAtech Activity Group Lining and Waterproofing

4 >> Typical membrane properties / 5 >>Trials and testing

4.3. Tensile strength, elongation and crack bridging

The crack bridging performance of spray applied membranes is a function of their tensile strength and elongation. Currently available spray applied
membranes can bridge cracks of at least 2.5 mm. If the designed structure requires greater crack bridging performance, this may be achieved with
increasing membrane thickness, but this must be subject to the agreement of the manufacturer.
Double-bonded membrane systems are usually able to bridge over cracks in both primary and secondary concrete linings.

4.4. Durability
The ingredients of most widely available spray applied membranes are based on established chemistries with proven track record.
The manufacturer of all products for the waterproofing works shall provide documentation to demonstrate the products are durable for the given
groundwater conditions and anticipated ground contaminations at each site, as specified in the project. Groundwater and ground conditions that
may potentially harm the membrane need to be considered. The final product is formulated to be stable chemically and to be resistant to water
containing pollutants that make the environment aggressive to the membrane, mostly acidic or alkaline. It should be noted that chemicals with similar
compositions, such as other hydrocarbons, may negatively affect the membrane.

4.5. Flammability

Despite recommendations that the membrane is covered with secondary lining concrete not long after it is cured to prevent damage, during
construction the membrane may be exposed in the tunnel environment for several weeks. It is therefore important that the membrane does not pose
a significant risk in the case of fire both during the spraying process and as a cured exposed membrane. This is important in order to ensure safety
and health of operatives and tunnel structural safety, and it complies with the specifications of the project (see Appendix A).

5. TRIALS AND TESTING

For many projects it will be necessary to demonstrate the membrane being applied in a site trial. Certificates of Compliance to the ITAtech Example
Specification (see Appendix A) shall be provided, together with other requirements requested by the designer.
Based on an in-situ application process to reflect the actual application condition, these trials shall demonstrate the suitability of materials (including
equipment, membranes, injections tubes, grouts and fixings) for use in an underground environment. Evidence of compatibility (for example bonding)
with the construction of secondary linings shall also be demonstrated.
Any changes in materials or supplier shall require new Certificates of Compliance, which shall also be submitted for acceptance.
Samples shall be taken from the trial area and tested fully in accordance with the Specification and additional designer requirements.

ITAtech Design Guidance For Spray Applied Waterproofing Membranes 17

6 >> Application requirements

The application equipment and skills for different spray applied membranes are quite different, but the following issues are valid for most systems:
•T
 he spraying equipment shall be capable of feeding materials at a regular rate and spraying the product from the nozzle at velocities which
promote adherence of the membrane to the surface with minimum rebound and maximum adhesion and coverage.
•T
 he equipment used should be capable of supplying the product components at the required pressures, volumes and ratios recommended
by the manufacturer of the waterproofing membrane.
•T
 he Contractor should ensure that all his nominated spraying operatives will have gained certified training in accordance with the ITAtech spray
membrane scheme (see Appendix B) prior to any application in the permanent works.
•R
 egular equipment maintenance and cleanliness are vital to ensure correct membrane applications.
•A
 n approved Quality Audit System is in place before trials and permanent works.

Correct preparation of the surface before membrane application is necessary for achieving a continuous membrane and avoiding material overconsumption.

6.1. Management of water ingress

The ease of application of a waterproofing membrane depends upon the level of water ingress through the substrate before membrane
application. The following table provides guidance in the preparation that may be required before the installation of a spray-applied
membrane.

Level of water ingress Preparation prior to membrane application

Dry: No moisture is detectable on the inside Membrane can be installed directly onto substrate once it is cleaned
Substantially dry: such moisture is found that there is no impact on of loose dust, grease and/or debris. Some membranes require the
the internal surface; e.g. if a piece of blotting paper or newspaper surface to be dampened before the membrane is applied.
is placed on a patch, it does not become discoloured as a result
of absorbing moisture.
Capillary wetting. There may be slightly moist patches but no
active running water ingress.
Weak trickling water in isolated spots Management of active water inflow is required prior to membrane
application, including:
a. Installation of local drainage strips
b. Sealing of local water inflow using quick setting mortar
c. Local injection
d. Temporary drainage using pipes
In drained tunnels, pipes/drainage strips can be incorporated into
a long term drainage solution or locked off once the waterproofing
membrane has cured.
Trickling/flowing water in isolated spots Source of water should be channelled or treated prior to membrane
installation.
Treatment options will be determined by the flow of water.
Solutions that prevent water travelling through the substrate (grouting
in or behind the lining) may be more effective than quick setting
materials on the surface.
Trickling/flowing water in many locations Extensive management of water ingress, as described above, is
usually required prior to membrane application. Careful evaluation of
the spray-applied waterproofing approach is required.

Table 1: Substrate preparation before membrane application

18 ITAtech Activity Group Lining and Waterproofing

6 >> Application requirements

6.2. Substrate surface quality and preparation If a regulating layer is used, a typical thickness of 1 to 3 cm with a
maximum aggregate size of 4 mm shall be applied to the primary
Spray applied membranes can accommodate irregularities (changes in lining prior to membrane application. It is important to ensure a proper
section and shape) in the substrate surface, but the surface texture / application of the regulating layer (e.g. surface preparation, correct
roughness must be closed, in order to prevent trapped air in the surface accelerator dosage that allows proper setting time, correct spraying
matrix from expanding under the membrane, creating pinholes. angle, correct air content and pressure), in order to avoid pitting
There are typically three levels of substrate roughness for application: and large craters on the surface, and achieve minimum bonding
• As-sprayed concrete with or without fibres or as excavated rock requirement of 0.5 MPa.
•S
 prayed smoothing layer or gunite (typically 4 mm aggregates)
•S
 mooth or float finished 6.3. Potential causes of local failures
The encountered substrate roughness and quality do influence the
time needed for the substrate preparation works, the consumption Potential causes of local failures with spray membranes include:
of material and the speed of application. It is recommended that very • Poor application due to poor workmanship, lack of training, quality
rough surfaces are regulated in order to maximise the efficiency of the control procedures and equipment.
waterproofing membrane, using a finer aggregate sprayed concrete or • Damage by construction teams before installation of final linings.
specific surface regulating material. For membrane installed in inverts at a protective sprayed or cast
concrete layer of similar quality to the final lining is used. The
thickness of the protection concrete shall be determined by the
As-shot sprayed concrete designer to meet all anticipated loads. For walls and crowns of
primary lining. tunnels some membrane are applied in two coloured layers that act
Spray applied waterproofing as a signal coat if damaged (the underlying colour is made visible
membranes can be sprayed and easily identified). Unlike sheet membranes, spray membrane
directly onto this surface, but are bonded to and therefore supported by the substrate and so
pinholing, membrane thickness are less prone to damage by subsequent construction activities.
and material consumption will • Exceptionally rough primary sprayed concrete lining substrates
be difficult to control. that cannot be effectively sealed.
• Excessively wet tunnel surfaces without adequate water
Using a regulating / smoothing
management (tunnel surface having running water).
layer of finer aggregate materials
will facilitate installation of a • Extended exposure to extreme environmental conditions, such as
high quality membrane, reduce heat, freezing, UV.
material consumption, and All the above conditions can be prevented by addressing each issue in
enable quicker application. the Specification and maintaining sufficient quality control. In all cases
the spray applied membranes must be QC checked and signed off
by all parties prior to secondary lining works as per the Specification
A completely smooth finish requirements.
requires additional labour, but
will permit the highest level of
quality control of membrane
application, depending on the
requirements of manufacturers.

Table 2: Substrate surface finishes

ITAtech Design Guidance For Spray Applied Waterproofing Membranes 19

7 >> Quality control

Quality control is required throughout the membrane application

process, and shall include final checking of the membrane to ensure
full compliance with project specifications, manufacturer’s instructions
or recommendations in this guidance document.

7.1. Coverage

A visual inspection of the spray applied waterproof membrane should

Figure 6: Thickness control: wet film thickness testing
be carried out on every defined application area. Areas in which the
substrate is still visible, the sprayed membrane is not suitably opaque • Thickness by measuring quantities in trials. The applied
or where the spray applied waterproof membrane is damaged, thickness can be assessed by measuring the quantity of spray
should be marked up with a compatible spray paint and an additional membrane used for the area over which it has been applied. A
layer of spray applied waterproof membrane shall be applied with a simple calculation gives the average thickness of the membrane
minimum lap of 200 mm on the adjacent membrane, or according to in the applied area. Under consumption will indicate the need
manufacturer’s recommendations. for an additional coat.
For all spray membrane systems, visual inspection or non-destructive • Two coat application. Applying the membrane in two coats can
testing assist detection of defective areas. These are simply spray offer better control of thickness and coverage than a single
painted and marked on the surface ready for repair (Figure 5). thick layer (Figure 7). This is often adopted with the reactive
membrane systems and is even further improved with different
colour 1st and 2nd coats to assist the nozzleman.

Figure 5: Quality assurance of sprayed membranes: visual

identification of defects Figure 7: Two colour application of waterproofing membrane (1st
coat orange, 2nd coat white)

7.2. Thickness

The routine testing of spray membrane coverage and thickness must

be undertaken, monitored and recorded on site quality inspection
check sheets. There are a number of methods normally used to
measure spray membrane thickness and are summarised below:
• The most effective and useful guide during application is for the
team to take wet film thickness measurements using a simple
depth gauge as shown in Figure 6. Measurement should be
carried out at the frequencies required by the specification or
manufacturer. For each test the thickness and location of the
test are recorded on a Quality Control Sheet. Under-thicknesses
can be remedied immediately or later. Figure 8: Optional method with cut-out inspection patches to
establish the applied membrane thickness

20 ITAtech Activity Group Lining and Waterproofing

7 >> Quality control

• Cut-out inspection patches, typically 50x50mm, are an optional 7.4. Integrity testing
method to establish the applied membrane thickness. These
patch tests should be taken randomly from all sections of the Holiday Detection, also known as Continuity Verification and Spark
tunnel profile, and the patches are easily repaired by over- Testing, is a test procedure that enables the detection and repair of
spraying. pinholes, voids and other defects in membranes and coatings. Such
defects are often termed as holidays or discontinuities.

7.3. Bond to Substrate

The bond strength of the membrane to the substrate should be 0.5

MPa or greater within 28 days to maintain the integral bond to eliminate
water paths between membrane and sprayed concrete. Depending
on the product selected, during membrane curing and development of
the bonding strength temporary drainage measures may be required to
drain any water inflow and to avoid build-up of water pressure, which
would retard the curing process of the membrane and lead to water

Figure 10 : Example of integrity testing to detect and repair pinholes,

voids and other defects in membranes

The test method is non-destructive, i.e. the material under test is not
damaged by the test, and is effective on non-conductive materials,
where the membrane or coating of sufficient dielectric strength acts as
an insulator. The test requires a high voltage DC power source, to one
terminal of which is attached an exploring wire connected typically to a
copper wire brush, and to the other terminal a return wire fixed to a sound
Figure 9: Tensile bond test of horizontal substrate with elcometer. ground point in the concrete substrate. The voltage is set according to
Dolly before and after testing (on the right) the thickness of the coating, such that if a full depth coating defect is
located in the membrane a spark from the will pass through the air gap/
paths in the interface between membrane and substrate. defect, forming a circuit and triggering a visual and audible alarm. When
Testing should be in accordance with the example specification in testing the installed material the wire brush/conductive strip is passed
Appendix A. The bond should have reached a sufficient value to across 100% of the surface under test; any defects identified are then
permit the safe application of the secondary sprayed concrete without immediately marked up and the indicated area locally repaired by hand
risk of material delamination, in accordance with the manufacturer’s with the same membrane system. The membrane in that area is then
recommendation. re-tested, and when it is found to be defect free is signed off.

ITAtech Design Guidance For Spray Applied Waterproofing Membranes 21

8 >> Design aspects

8.1. Lining configurations During the last two decades, significant progress was made in
concrete technology (mix-design), with advanced admixtures (e.g.
Typical tunnel lining configurations include double-shell lining (DSL), water reduction, alkali-free accelerators), as well as in the application
single shell lining (SSL) and composite shell lining (CSL), as shown of sprayed concrete, with sophisticated spraying robots, and in
on Figure . waterproofing of tunnel linings (spray applied membranes). All these
Sprayed concrete single shell linings (SSL) have been built for factors have enabled designers to use sprayed concrete linings
decades, e.g. for the construction of water tunnels, caverns, and increasingly for long term service life.
transportation tunnels. It is a permanent sprayed concrete lining
consisting of a single layer or several layers placed at different times,
8.2. The composite shell lining system
without a waterproofing membrane. The main design issues of SSL
are related to the structural interaction between primary (outer) lining Composite shell lining (CSL) systems are based on the single shell
and secondary (inner) lining, which are usually built at different times lining approach and consist of two concrete linings, which are usually
and thus submitted to different stresses and strains, as well as to installed at different stages, with a double-bonded spray-applied
watertightness of the sprayed concrete lining. waterproofing membrane embedded between them. The secondary
(inner) lining may consist of sprayed concrete (often fibre reinforced)
or cast in-situ concrete. Both concrete and waterproofing membrane
are vital functional parts of this system. The following picture shows
schematically an example of a composite shell lining with an
embedded double-bonded spray-applied waterproofing membrane
between primary and secondary linings.

Figure11: Typical tunnel lining configurations (Thomas, 2009)

Traditionally, the lining of tunnels and other underground structures

excavated by conventional methods has been designed and built
based on the double-shell lining (DSL) approach. According to this
approach, initially a temporary (and low quality) sprayed concrete
lining is constructed to stabilise the opening after excavation and to Figure 12: Example of a composite shell lining with a double-bonded
contain only short to medium-term loads (primary lining). Later on a spray-applied waterproofing membrane
permanent cast in situ concrete lining is installed to contain long-term
loads, and attend the requirements of serviceability and durability
After application the membrane adheres to the primary lining and
(secondary lining). Watertightness is achieved by the installation of a
starts developing its bonding strength and curing. When curing of the
waterproof sheet membrane between primary and secondary linings,
membrane has finished, a secondary concrete lining (sprayed or cast
which acts additionally as a separation / sliding layer, reducing the
insitu concrete) or a protective concrete layer can be installed against
potential of shrinkage cracking on the secondary lining. Under some
the membrane.
project conditions, e.g. deep tunnels with anticipated high water
pressure and required fully drained conditions, the DSL approach is After installation of the secondary lining / protective layer onto the
the only possible approach to build the underground structure. cured membrane, bonding between the two layers develops and
provides additional safety to the composite lining system.

22 ITAtech Activity Group Lining and Waterproofing

8 >> Design aspects

8.2.1. The principle of composite action In the design of composite lining systems the shear stress in the joint
concrete-membrane must be limited to the admissible shear stress
The principle of composite action can be demonstrated by comparing according to Design Standards, to avoid any tensile failure, as it is
the action of two joists placed one on top of the other. If these are simply usually required for the design of single shell linings with two distinct
placed one on top of the other and loaded as a beam there will be some sprayed concrete linings.
relative movement between the two. However, if these are physically
connected, the bending strength and stiffness are significantly improved
as the two will act together as a single unit with double the thickness. 8.2.4. Waterproofing approaches

CSL can usually be designed as a undrained (fully tanked) structure

8.2.2. Improvement in performance against limited water pressure or as a systematically or locally drained
structure (see also chapter 3), depending on the requirements of the
Primary and secondary linings installed without a waterproofing project.
membrane are often thought as acting as a single shell thanks to the
influences of geometry, bond and shear connection through surface
roughness. In many cases however, this solution does not offer a 8.2.5. Introduction to numerical modelling of CSL systems
suitable watertightness in the long term. Spray applied waterproofing
The composite lining must be able to withstand all potential loading
membranes allow the benefits of both options by connecting the
conditions from the ground, ground water and surface loads throughout
primary concrete lining to the secondary concrete lining by means of
the design life of the tunnel. The lining structure should be watertight,
a fully bonded (double-bonded) membrane that can transfer some of
durable, as well as capable of accommodating the loads of internal
the shear forces, allowing the linings to work together. Aside from the
structures such as lighting canopies and ventilation fans and have
obvious waterproofing advantages the fully bonded membrane is also
a surface finish to achieve the required reflectance and aesthetic
structurally advantageous.
appearance.
Testing at SINTEF Material Laboratory, Norway has suggested that
To achieve composite behaviour and guarantee the structural
energy absorption post-initial cracking has increased in the case of
effectiveness of the system, a bond needs to be achieved between the
a composite lining made of fibre reinforced sprayed concrete, with a
concrete layers and the sprayed membrane to permit the transfer of
sprayed membrane in-between two layers, subjected to central loading
normal and shear forces between the primary and secondary layers.
in comparison to the same concrete sample without membrane.
The bond strength required at the interface between the primary and
If the primary lining is designed for permanent purposes, and suitable
secondary lining to permit the composite action must be evaluated for
load transfer through the spray applied membrane to the secondary
each project. The prevailing load conditions must be considered before
lining occurs, designers have the opportunity to significantly reduce the
coming to a judgment on whether or not a composite lining solution is
lining thickness in comparison to the assumption that the whole final
achievable.
load is acting on the secondary lining only.
The properties of the interfaces between the concrete and the
Research at the University of Southampton (Su, Bloodworth & Haig,
waterproofing membrane are required for numerical simulation of the
2013) is exploring the influence of membrane thickness and interface
structural CSL. These properties are usually taken from back-analysis of
conditions on the degree of transfer between the primary and secondary
linings through the membrane. Such data can give further confidence shear test data. Shear test curves can be replaced with curves derived
in the degree of composite action allowable in the design as well as from numeric simulations of the shear tests.
provide input parameters for numerical modelling. Typical interface parameters used in numerical models are the angle of
interface friction, the interface cohesion, as well as the Interface shear
and normal stiffness.
8.2.3. Typical failure mode
The exact parameters for the interface elements may vary depending on
The adhesive tensile strength of the membrane is a significant parameter the theory implemented in each numerical modelling program. Therefore,
for the creation of an effective bond. It should be high enough to prevent it is recommended that the input parameters for the model are derived
membrane delamination and to avoid migration of water in the interface by first back-analysing test data and calibrating the numerical model.
between membrane and concrete lining as described in Section 4.1.1.
The following types of tensile failure can occur within the composite shell
lining, depending on the part of the bonded lining system which fails
under stress:
• Tensile failure due to cohesion break in the concrete
• Tensile failure due to adhesion break between concrete and membrane
• Tensile failure due to cohesion break within the membrane layer

ITAtech Design Guidance For Spray Applied Waterproofing Membranes 23

>> Bibliography

Holter, K. G., & Nermoen, B. (2011). Permanent Waterproof Tunnel Lining Based on
Sprayed Concrete and Spray-Applied Double- Bonded Membrane. Proceeding of the
World Tunnel Congress 2011, Underground Space in the Service of a Sustainable Society
(pp. 330-340). Helsinki: ITA-AITES.

Su, J., Bloodworth, A. & Haig, B. (2013). Experimental Investigation into the Interface
Properties of Composite Concrete Lined Structures. Proceedings of the World Tunnelling
Congress 2013. Geneva: ITAAITES.

Thomas, A (2009). Sprayed Concrete Lined Tunnels, An Introduction.

Published by Taylor and Francis, UK 2009.

24 ITAtech Activity Group Lining and Waterproofing

ITAtech Design Guidance For Spray Applied
Waterproofing Membranes

Appendix A:
Example Specification
>> Table of contents

1. Performance requirements on waterproofing ............ 27

2. Membrane properties and testing standards................. 28

3. Pre-selection trial...................................................................... 30

4. Application Requirements......................................................... 31
4.1. Management of Water Ingress .............................................................31

4.2. Preparation of substrate, roughness and surface features ..31

4.3. Substrate cleanliness ...........................................................................31

4.4. Tunnel conditions during application of membrane ....................32

4.5. Defects and Repair of local membrane.............................................32

5. Quality control ........................................................................... 33

5.1. Quality Control Testing during Construction...............................33

5.2. Supervision .................................................................................................34

5.3. Records .......................................................................................................34

6. Secondary concrete linings .................................................. 34

7. References and Standards....................................................... 35

APPENDIX A-­1:
Example Quality Control Check Sheet............................... 36

APPENDIX A-­2:
Altered procedure for the watertightness test.......... 37

26 ITAtech Activity Group Lining and Waterproofing

1 >> Performance requirements on waterproofing

(1) The tunnels shall incorporate a waterproof membrane in order to achieve the waterproofing class as defined in Table 1 below:

Waterproofing Definition for Characteristic of the waterproofed inner soffit

Class impermeability General
on the inner soffit

The inner soffit shall not show any moisture areas.

1 Completely dry
Acceptable amount of water in the tunnel: no water.

On the inner soffit, weak moisture penetration shall only appear on max. 10% of each section
surface (visible as a dark colour change on the concrete surface).
On dry hands contacting weak moisture areas no evident marks of water shall be visible
2 Largely dry afterwards. Disposed blotting paper or absorbent newsprint shall not change in colour due to
moisture absorption.
Acceptable amount of water in the tunnel: any quantity less than the acceptable amount of
waterproofing class 3.

On the inner soffit, weak moisture penetration shall only appear on max. 10% of each structure’s
section surface (visible as a dark colour change on the concrete surface).
3 Slightly wet
Acceptable amount of water in the tunnel: general 0.02 litre/m2/d, for less than 50 m of tunnel
lenght 0.1 litre/m2/d.

Table 1: Water-­‐tightness Classes (Based On Ril853)

(2) The waterproofing system used shall be suitable for the Works and the local conditions of ground and groundwater. Any expected
movement of the structural elements caused by shrinkage, temperature changes and settlements, should not result in the waterproofing
system losing its waterproofing properties.
(3) All the materials to be used for waterproofing shall be compatible with each other, as well as with any bordering materials such as
concrete. Any harmful chemical influences shall be prevented.

ITAtech Design Guidance For Spray Applied Waterproofing Membranes 27

2 >> Membrane properties and testing standards

(1) The spray applied waterproofing membrane product shall be demonstrated to conform to the properties identified in.

(2) Table 2 based on laboratory based samples and standard preparation techniques. Independent test certificates to demonstrate
conformity shall be submitted.

(3) The designer should assess the environmental conditions of the project and define additional relevant test methods and requirements.

(4) Standard Test Method for Tensile Strength of Concrete Surfaces and the Bond Strength or Tensile Strength of Concrete Repair and
Overlay Materials by Direct Tension (Pull-off Method)

Property Test Method Minimum Requirement

ASTM 1583/C 1583M (Pull-off Method) or 0.5 MPa

Bond to substrate
EN ISO 4624 (but using a 50mm dolly) or EN 1542 within 28 days after membrane application

Double bond
(to substrate
and inner lining). 0.5 MPa
ASTM 1583/C 1583M (Pull-off Method)
Only in the case within 28 days after application of final concrete layer
of double-bonded
membranes.

Based on EN 12390-8, with adaptation for inclusion

of a spray applied membrane (see Figure 1 below and
Watertightness Zero penetration of water through the membrane
Appendix A-2 of this document ); Based on EN 14891,
Part A7, for the concrete mix design

EN 1062-7 Class A5
Crack Bridging
Method A: C1 Static Tensile Test - Measured at 20°C Min. 2.5 mm

Class E,
Flammability EN ISO 11925-2
as defined in EN 13501-2+A1

a) There shall be no visual sign of degradation;

According to EN 14414, Method A (acid solutions) and
b) Comparison of the tensile properties (tensile
Method B (alkali solutions). Resistance against chloride
strength and elongation at break) of the tested
(at 10% chloride concentration).
Chemical resistance specimen with those of a control sample. The
Testing based on EN 14414 Method A or B shall be
acceptance criteria shall be a maximum change of
according to the groundwater chemistry of the project
25% compared to the control sample tensile strength
as specified by the designer.
and elongation at break of the membrane.

a) There shall be no visual sign of degradation;

b) Comparison of the tensile properties (tensile
strength and elongation at break) of the tested
specimen with those of a control sample. The
According to EN 14415, in hot water (Method A), and
Resistance to leaching acceptance criteria shall be a maximum change of
aqueous alkaline liquids (Method B).
25% compared to the control sample tensile strength
and elongation at break of the membrane.
c) The loss in mass of the sample shall not be greater
than 5 % compared to the control sample.

Table 2: Essential properties of the spray applied waterproofing membrane

28 ITAtech Activity Group Lining and Waterproofing

2 >> Membrane properties and testing standards

150 mm diameter and length core

Membrane on the surface of core

Water inlet
28 days at 500 ± 50kPa

Figure 1: EN 12390-8 test method altered for inclusion of a spray applied waterproofing membrane

(5) All material suppliers shall have certification to show compliance with ISO 9001 and provide the certificate of the FPC (Factory
production control) of the product.

(6) Materials shall not contain either substances classified as carcinogens, mutagens or teratogens (substances toxic to reproduction) or
substances classified as respiratory hazards in accordance with local or national regulations.

(7) All waterproofing system components shall be designed for the minimum design life of the structure.

ITAtech Design Guidance For Spray Applied Waterproofing Membranes 29

3 >> Pre-selection trial

(1) A pre-construction trial may be required for the proposed membrane system.
(2) The Contractor shall submit for acceptance prior to the trial a method statement and quality plan. These documents shall be prepared
in conjunction with the applicator and endorsed by the manufacturer of the material, describing the details of the waterproofing works
including protective measures, at all stages. As part of the trial the Contractor shall demonstrate the temporary water management
techniques they wish to adopt. If, during trials, adjustments to these documents must be made, these shall be submitted for acceptance
before commencement of the full waterproofing works.
(3) During trials, the Contractor shall demonstrate compliance with material requirements and testing criteria outlined in this Specification.
This should be done with the minimum thickness of membrane to be accepted.
(4) The trial shall, where possible, be representative of the conditions to be encountered during the full project installation. The spray
applied waterproofing membrane product shall be demonstrated to conform to the performance properties shown in Table 2. If a real
tunnel substrate is not available, tested sections shall be taken from test panels, at least 1000 mm by 1000 mm, by 150 mm thickness
(to allow water penetration cores to be taken)
(5) The trial shall be used by the Contractor to demonstrate the suitability of the materials, equipment and construction methodology and
the competence of operatives. As a minimum the trial shall include the following items:
• Installation of water management techniques,
• Application of smoothing or regulating layer (if required),
• Application (including equipment and skills of the application team) of the spray applied membrane and bond to the substrate,
• Quality control systems and testing methodologies for ensuring coverage and thickness, including the required testing regime,
• Demonstration of the methods used to test the in-situ membrane to ensure that complete water tightness has been achieved prior
to the secondary lining be installed
• Repair techniques for any defects detected in the spray applied waterproofing membrane,
• Demonstration that a sprayed concrete lining can be applied inside the fully cured spray applied waterproofing membrane (including
the main tunnel crown) with no observed instability, such as sagging or sprayed concrete fallout.
• Demonstration of repair techniques applied when a leakage is detected after installation of the secondary lining.
• Demonstration of how an overlap joint is prepared and installed.
• Demonstrate how to apply the membrane in zones with construction joints
• Demonstrate double-bonded test method in table 3 for composite shell linings.
(6) The trial shall be subject to an approvals process and additional waterproofing and secondary lining works may not proceed until both
the Contractor and Project Manager are satisfied and the Project Manager has accepted all aspects of the trial.

30 ITAtech Activity Group Lining and Waterproofing

4 >> Application requirements

(1) All waterproofing membranes shall be installed and tested in accordance with the manufacturer’s instructions or recommendations
as described in the method statement and materials shall be mixed in accordance with the manufacturer’s instructions, using
recommended equipment.
(2) Testing shall be undertaken as necessary to ensure satisfactory functioning of the membrane at each stage of the installation.
(3) Defective waterproofing membranes shall be repaired in accordance with the manufacturer’s instructions or replaced.
(4) All waterproofing applicators will have undergone application training determined by the manufacturer of the membrane and be
experienced and certified (by the manufacturer) in the installation and testing of the waterproofing system.

4.1. MANAGEMENT OF WATER INGRESS

(1) Where water ingress through the primary lining is such that it may affect the successful installation of the spray applied waterproofing
membrane, the Contractor shall use water management techniques. This water management shall be maintained throughout the
membrane placing process, and shall be so arranged that water pressure behind the membrane cannot develop during construction
of the tunnel secondary lining.
(2) Temporary drainage (e.g. dimple sheet stripes, drainage channels) shall have sufficient capacity for the encountered inflow of water,
they should be resistant to damage from spraying and they should be flexible to achieve a close fit to the surface.
(3) In case of using dimple sheets, they shall be a minimum of 500 mm in width and shall have dimples or surface relief features such that
water is directed along the strip to a collection point. Drainage strips shall be adequately fixed by a method proposed by the contractor,
for example, via shot fired nails, with rubber (e.g. self-sealing) washers/collars, on either side at minimum 250 mm centres.
(4) Where leak remediation measures are to be through grouting, the methodology shall be submitted for acceptance prior to the application
in the works. Supporting documentation and evidence shall include:
Grout plan procedure and sample of grouting materials including data sheets and evidence of performance in similar conditions.
On-site demonstration of injection pressure. The structural capacity of the structure shall not be exceeded.

4.2. Preparation of substrate, roughness and surface features

(1) The final requirements for the surface that will receive the waterproofing system shall be in accordance with the guidance given by the
supplier of the sprayed membrane.
(2) Where the required surface finish cannot be achieved with the primary sprayed concrete layer, a finer aggregate sprayed concrete layer
shall be applied to regulate the substrate.
(3) No further waterproofing application stages shall be carried out until the surface finish standard to be achieved has been agreed as
satisfactory to the waterproofing supplier and Contractor.
(4) The substrate shall be suitably dry for the 24 hours prior to membrane application.
(5) Bars used for the purpose of providing support to secondary lining reinforcement shall be drilled and inserted prior to the application of
the waterproofing membrane. The bars shall be cleaned so as to allow adequate bond with the spray applied waterproofing membrane.
(6) Pull-off tests to verify if substrate surface strength is sufficient to comply with membrane bonding requirements (see table 3).

4.3. Substrate cleanliness

(1) Before applying the spray applied waterproofing membrane, the sprayed concrete surface shall be thoroughly cleaned and pre-wetted
(as required by membrane manufacturer) using compressed air and/or water (without oil contamination) in accordance with guidance
given by the membrane supplier.
(2) High pressure water and/or air cleaning should be used in the case that the substrate has surface contaminations of old soot, soil,
debris, dust, oil, grease, loose particles hardened dust, deteriorated concrete or any remains of an external surface curing agent.

ITAtech Design Guidance For Spray Applied Waterproofing Membranes 31

4 >> Application requirements

4.4. Tunnel conditions during application of membrane

(1) The substrate temperature during application should be between +5°C and +40°C.
(2) Ventilation shall be as required by the manufacturer and all local/national regulations.
(3) When installing the spray applied waterproofing membrane, no other works shall be carried out in the vicinity which may cause
personnel or equipment to come into contact with the spray applied waterproofing membrane before it has cured. If it is likely that
excessive dust may be generated in the vicinity of the works (vehicle movements etc.) then dust suppression measures shall be put
in place until the membrane has cured.
(4) Lighting shall be sufficient to allow efficient installation and inspection of the spray applied waterproofing membrane.
(5) If the application of the spray applied waterproofing membrane products present fire, occupational health and/or environment related
hazards, notably in respect to the confined space environment, then measures shall be identified and put in place to control these
hazards. Appropriate measures shall include, but not be limited to:
• Ventilation requirements and air quality monitoring
• Fire detection and suppression
• Personal Protective Equipment
• Exclusion zones
• Eye wash and first aid facilities.

4.5. Defects and Repair of local membrane

(1) Areas in which the substrate is still visible, or where the spray applied waterproofing membrane’s integrity is impaired, shall be marked
up, e.g. with surveyor paint, and an additional layer of spray applied waterproofing membrane applied with a minimum lap according
to manufacturer’s recommendations around the area.
(2) If, after repairs, any section of spray applied waterproof membrane still does not meet specified requirements it shall be removed and
replaced. The cause of the problem shall be identified and remedial action taken before placing any further spray applied waterproofing
membrane.
(3) Adjacent sections of spray applied waterproofing membrane shall overlap by a minimum as defined by the manufacturer. Spray applied
waterproofing membrane shall only overlap an existing section of membrane if the surface is clean of dust and contaminants.

32 ITAtech Activity Group Lining and Waterproofing

5 >> Quality control

5.1. Quality Control Testing during Construction

(1) The spray applied waterproofing membrane shall be tested in accordance with Table 3 below throughout the application process with
the results recorded and monitored.
(2) All defects and variations from the requirements as identified by the testing methods in Table 3 shall be repaired and retested.

Parameter Test Method Frequency Pass/Fail Criteria

According to supplier’s
Quality of substrate instructions and design of All surfaces According to chapter 4.2 and 4.3
concrete

Quality of substrate Every 500 m2 or as required by the

EN ISO 4624 Min. 0.5 MPa
(strength of surface) manufacturer

A visual inspection to be carried out

Coverage/Continuity Visual continuously while the membrane is Full coverage
applied and following application.
In-situ post application non-
destructive test as identified by
Coverage /Continuity manufacturer (if available); e.g. All surfaces No holes identified
Holiday testing with methacrylate
membranes (ASTM D 4787)
Minimum 10 tests per 100m² Minimum thickness as per
Wet film thickness by means of
(evenly spread across the full area, manufacturer’s recommendations and
depth gauge
not localised) design requirements achieved in all tests.

Minimum kg/m2 to match quantity

Application quantity measurement Per day identified during trials to achieve
thickness as required
Thickness
The average of five spot measurements
shall not be less than the specified dry
Cured thickness 50 mm by 50 film thickness.
On request of the Project Manager
mm patches No single spot measurement shall be
less than 90% of the specified dry film
thickness.

ASTM D7234 Min. 0.5 MPa

Bond to substrate Pull-off adhesion strength of within 28 days after membrane
(for single bonded Min. 3 tests per day
membranes) coatings on concrete using application according to supplier’s
portable pull-off adhesion testers recommendations

Based on ASTM D7234,

Double bond (to Pull-off adhesion strength of
substrate and inner Preliminary tests with min. 5
coatings on concrete using Min. 0.5 MPa
lining). Mandatory samples from each trial area at the
portable pull-off adhesion 28 days after application of final
for composite shell project beginning. On request of
linings (with double- testers, considering additional concrete layer
the Project Manager from then on.
bonded membrane). adhesive failure modes due to the
secondary (inner) concrete lining.

Table 3: Construction Testing for spray applied waterproofing membranes

ITAtech Design Guidance For Spray Applied Waterproofing Membranes 33

5 >> Quality control / 6 >> Secondary concrete linings

5.2. Supervision

(1) Dedicated waterproofing supervision (independent of the applicator) with suitable experience of and training (with certification from the
manufacturer) in the installation of similar systems shall be present on site for all periods of waterproofing application.

5.3. Records

(1) The Contractor shall keep records, during both the pre-construction trials and the main works, of the following items on a standardised
approved check-sheet, as per examples included in this specification (see Appendix A-1 for quality records):
•T
 he inspection of the substrate prior to installing the waterproofing membrane.
•T
 he location of any water management measures which are undertaken, such as drainage strips and injection tubes, their terminal
units and expansion sealant.
•A
 ll quality control tests, identifying the section of work to which they relate.
•R
 ecords of any repairs and retesting carried out.
•T
 he inspection and testing of the waterproofing membrane, prior to installation of the secondary lining.
•T
 he delivery tickets for each consignment of each material as retained by the Contractor.

6. Secondary concrete linings

(1) Secondary concrete linings which are installed against the spray applied waterproofing membrane layer shall be installed in such a way
that there is no damage to the integrity of the spray applied waterproofing membrane.
(2) The secondary concrete lining shall be installed as soon as possible following a period of time (as identified in Manufacturer’s Information
and detailed in the method statement) that allows complete curing of the spray applied waterproofing membrane. The spray applied
waterproofing membrane shall not be without a secondary concrete lining for a period of time that results in a build-up of water
pressure behind the membrane.
(3) Installation of secondary lining reinforcement shall where practical negate the need for protrusions or penetrations of the waterproofing
membrane. The contractor shall demonstrate his proposed methodology for reinforcement installation.
(4) Starter bars, where used, shall have been encapsulated by spray applied waterproofing membrane, as specified by the membrane
manufacturer, prior to installation of secondary concrete layers.
(5) Concreting and other tunnelling activities associated with the secondary lining works shall not result in contamination of the waterproofing
works. Where required, protection shall be provided to the spray applied waterproofing membrane when adjacent sections of concrete
lining installation are underway.
(6) If a break of greater than 24 hours is anticipated, any un-compacted concrete overspray that has adhered to the membrane shall be
cleaned off before curing: leaving a clean surface of membrane to receive the secondary lining.
(7) Curing compounds/agents (such as acrylics or waxes) applied to the secondary lining shall not come into contact with the spray
applied waterproofing membrane.
(8) Before a section of secondary lining is installed the waterproofing membrane shall be checked for defects by a suitable and proven
non-destructive test method. Installation of the secondary lining cannot take place until the area is signed off by the independent
waterproofing supervisor; two days prior concreting works is recommended.

34 ITAtech Activity Group Lining and Waterproofing

7 >> References and standards

ASTM International. (2004). ASTM C1583/C 1583M

Standard Test Method for Tensile Strength of Concrete Surfaces and the Bond Strength or Tensile Strength of Concrete Repair and Overlay
Materials by Direct Tension (Pull-­‐off Method). USA: ASTM International.

ASTM International. (2008, June). ASTM D 4787

Standard Practice for Continuity Verification of Liquid or Sheet Linings Applied to Concrete Substrates. USA: ASTM International.

ASTM International. (2012, July). ASTM D7234

Standard Test Method for Pull-­‐Off Adhesion Strength of Coatings on Concrete using Portable Pull-­‐Off Adhesion Testers. USA: ASTM
International.

European Committee for Standardization (CEN). (1999, April). European Standard EN 1542
Products and systems for the protection and repair of concrete structures. Test methods -­‐ Measurement of bond strength by pull-­‐off.
Belgium: CEN.

European Committee for Standardization (CEN). (2003, May). European Standard EN ISO 4624
Paints, varnishes and plastics. Pull-­‐off test for adhesion. Belgium: CEN.

European Committee for Standardization (CEN). (2004, May). European Standard EN 1062-­‐7
Paints and varnishes -­‐ Coating materials and coating systems for exterior masonry and concrete -­‐ Part 7: Determination of crack bridging
properties. Belgium: CEN.

European Committee for Standardization (CEN). (2004, May). European Standard EN 14414
Geosynthetics -­‐ Screening test method for determining chemical resistance for landfill applications. Belgium: CEN.

European Committee for Standardization (CEN). (2004, May). European Standard EN 14415
Geosynthetic barriers -­‐ Test method for determining the resistance to leaching. Belgium: CEN.

European Committee for Standardization (CEN). (2009, February). European Standard EN 12390-­‐8 EN
Testing hardened concrete -­‐ Part 8: Depth of penetration of water under pressure. Belgium: CEN.

European Committee for Standardization (CEN). (2009, September). European Standard EN 13501-­‐2+A1
Fire classification of construction products and building elements -­‐ Part 2: Classification using data from fire resistance tests, excluding
ventilation services. Belgium: CEN.

European Committee for Standardization (CEN). (2010, November). European Standard EN ISO 11925-­‐2
Reaction to fire tests -­‐ Ignitability of products subjected to direct impingement of flame -­‐ Part 2: Single-­‐flame source test. Belgium: CEN.

ISO. (2008). International Standard ISO 9001

Quality management systems — Requirements. Switzerland: ISO.

ITAtech Design Guidance For Spray Applied Waterproofing Membranes 35

 Spray  Applied  Waterproofing  Membrane  –  Quality  Control  Check  Sheet  

Example  
APPENDIX A-1 >> Example quality
 
control check sheet

   
 
36 ITAtech Activity Group Lining and Waterproofing
 Spray  Applied  Waterproofing  Membrane  –  Quality  Control  Check  Sheet  

Example  
APPENDIX A-1 >> Example quality
 
control check sheet

Spray  Applied  Waterproofing  Membrane  –  Quality  Control  Check  Sheet  

PROJECT  NAME,  COUNTRY    

Tunnel/Structure  
 
 
       
 
 
Date/Time  
 
 
   

Regulating  Layer  
 
□  
 
Required  thickness    
     
mm    
 
Shift/Team  
 
 
   

Required  thickness   Approved  Applicator  Name   Certificate  No.  

□  
Waterproofing     mm  
membrane   Required        
kg/m
2
 
consumption  rate  
                 

□  
Ambient  Temp.   Substrate  Temp.   Rel.  Humidity  %  
Secondary  lining   Required  thickness     mm    

Plan  of  structure  

Chainage   LHS     Sidewall   Crown/Invert   Sidewall   RHS     Testing   undertaken   &  
(m)   Footing   Footing   comments.  Indicate  actual  
2
consumption  rates  kg/m  
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
Key  

 
 

 
Inspection  &  Approvals   Representative   Name   Signature   Date   Time  

□  
 
Regulating  layer  approved   Contractor  Representative          

□  
 
Spray  wp  membrane  approved   Supervisor  Representative          

□  
 
Secondary  lining  approved   Client  Representative          

□  
  Details  of  re-­‐work  to  permit  approval:  
Section  not  approved  
 
Re-­‐inspection  date/time:      
 
 
 
 

   
 
ITAtech Design Guidance For Spray Applied Waterproofing Membranes 37
APPENDIX A-2 >> Altered procedure for the watertightness test

Sample preparation:

• Specimens according to EN 12390-8 in terms of shape, dimensions, curing and storage produced of porous concrete
• Concrete mix design according to EN 14891 - A7 (water – cement ratio ≥ 1.0; max. grain size 16 mm)
• Surface preparation of one of the previously moulded faces according to EN 12390-8. Alternatively the specimen surface can be grinded
flat prior to the membrane application.
• 3 specimens shall be prepared and tested in parallel.

Membrane application:

• The concrete substrate surface shall be clean and comply with the supplier’s requirements.
• The membrane material shall be applied according to the supplier’s instructions in order to achieve required membrane thickness.
• The membrane material shall be cured according to the membrane supplier’s instructions.

Test procedure:

• 3 test specimens shall be tested in parallel in a test stand according to EN 12390-8.

• Water pressure of (500 ± 50) kPa shall be applied for 28 days.
• After 28 days the specimens are removed from the test stand and broken according to EN 12390-8
• A failure of the membrane may result in water outlet from the specimen surface prior 28 days or a moisture horizon at the fracture face
which shall be marked e.g. with a pencil
• Water outlet from the specimen surface before 28 days shall be recorded. The test of this specimen shall be cancelled.
• The thickness of the membrane shall be measured after braking the specimen and cutting it off the surface

Cube 150 mm
or core 150 mm diameter

Membrane on the bottom side

of the specimen

Water inlet
28 days at 500 ± 50kPa
EN 12390-8 test method altered for inclusion of a spray applied waterproofing membrane

38 ITAtech Activity Group Lining and Waterproofing

ITAtech Design Guidance For Spray Applied
Waterproofing Membranes

Appendix B:
Training Certification

ITAtech Design Guidance For Spray Applied Waterproofing Membranes 39

>> Table of contents

1. Introduction................................................................................... 41
2. Education.......................................................................................... 42
2.1. Education for applicators.....................................................................42

2.2. Education for engineers, designers and supervisors..................42

3. Certification................................................................................... 43
3.1. Examiners.....................................................................................................43

3.2. Applicator....................................................................................................43

4. Attachments.................................................................................... 43

40 ITAtech Activity Group Lining and Waterproofing

1 >> Introduction

Durable, robust engineering solutions require the combination of ITAtech (AG Waterproofing) will provide guidelines for the course
high quality products and competent, skilled applicators working in content for both levels of education courses.
accordance with thorough methodologies. Products are controlled by
strict quality systems and their applicability is defined by performance The certification scheme operates through examiners who assess
requirements given in national and/or project targeted specifications. experienced applicators for their theoretical and practical skills
It is essential that methods for establishing competence of applicators at their workplace. The examiner himself has a wide experience
is available to those specifying these products for projects, to ensure in underground construction and waterproofing applications,
the material potential is met. particularly in spray applied membranes, and has been independently
accredited by an independent body (e.g. CUC) through attendance
Training and certification is available for sprayed concrete application at an Examiner Assessment Course.
through the EFNARC and ACI nozzle-man schemes, but at this
point, no equivalent international standard has been set for those The certification scheme is not a training scheme for neither the
applying spray applied waterproofing membranes. applicator nor the examiner as both are expected to have a high level
of competence before applying. If training is required, the participants
This Spray Applied Membrane Training and Certification Scheme (especially when starting application of sprayed membranes) can
(SAMTaCS) is an answer to the construction industry’s need to have make use of education courses. However, the support documents
a neutral and objective procedure for assessing and certifying spray to accompany the scheme and pre-training based on these notes
applied waterproofing membrane applicators. could be included by those doing the assessment.

The aim of the Spray Applied Membrane Training and Certification Certificates are issued to the applicators through the independent
Scheme is to improve the overall quality of application of spray applied body which should be endorsed by a well-accepted authority like
membranes by providing an independent course for recognition of ITA-CET on the recommendation of the examiner. The certificates
competent operators and their working methods. are valid for 5 years and can be prolonged once by a theoretical
assessment. The practical and theoretical assessment will have to
The scheme consists of the following elements: be redone, after a maximum period of 10 years.
- Education and training courses for applicators
- Education courses for supervisors and engineers
- Certification of applicators who have already gained the necessary
experience and can demonstrate their technical knowledge and
practical ability.

ITAtech Design Guidance For Spray Applied Waterproofing Membranes 41

2 >> Education

The education courses are aimed at applicators and engineers/ During the practical application work each participant has to apply
supervisors gaining their first experiences with spray applied spray applied membrane and take into account the aspect mentioned
waterproofing membrane systems and technologies. in the theoretical part and additional:

- Control of thickness of membrane

2.1. Education for applicators - Curing of membrane if required

The education course for applicators includes: The practical part should take at least 10 hours.
- Theoretical information
- Practical application work 2.2. Education for engineers, designers and
The theoretical part will focus on basic understanding of the supervisors
application of spray applied membranes; appreciating what is
Education for engineers, designers and supervisors will also include
necessary to carry out proper practical application. The following
theory, which will be followed by practical demonstrations.
topics will be included:
- Assessment of the underground The theoretical part will include:

- Roughness of surface to receive membrane - Concept of water-protection of underground structures

- Wetness of surface - Systems of water-protection
- Equipment operation - Specification requirements and design criteria
- Proper operation of equipment - Preparation requirements
- Quality check of delivered material (age, storing conditions,..) - Roughness of surface to receive membrane
- Maintenance and cleaning of equipment - Wetness of surface and methods of dealing with water ingress
- Drainage systems which could be applied with sprayed prior to membrane installation
membranes - Drainage systems which could be applied with sprayed
- Issues of application membranes

- Controlling application thickness - Issues of application

- Construction joints - Construction joints

- Repairing of any defects - Joints with other materials

- Joints with other materials - Quality control

- Quality control measures - Health, Safety and environmental issues

- Health, Safety and environmental issues - Handling of material

- Handling of material - Personal protection equipment

- Personal protection equipment - Cleaning of machinery

- Cleaning of machinery During the practical demonstration the participants will see typical
application processes and learn how to assess the process and
examine the quality of the installed membrane. By the end they
should feel comfortable in being asked to sign an installed membrane
off as complete.

42 ITAtech Activity Group Lining and Waterproofing

3 >> Certification

Certification for applicators of spray applied membranes will be

given by an independent certification body (ICB) on the basis of
an assessment by an experienced examiner, who will evaluate the
applicator at his construction site. The examiners are to be approved
according to a standard scheme.

3.1. Examiners

The Examiner must be a named individual, not an organisation.

The Examiner shall have a wide experience of underground

construction and spray applied membrane applications. Examiners
shall be able to demonstrate suitable experience within the industry.
The Spray Applied Membrane Examiner Assessment Course will
be organised by an organisation with the necessary facilities to run
both classroom and practical spray applied membrane application
assessment in accordance with the scheme. The scope of the
assessment course will cover the following themes:
- Aims of the Certification Scheme
- Theoretical workshop highlighting the key topics of application
of sprayed membranes to gain a common understanding
among the examiners
- Practical workshop demonstrating best practice application
and testing of spray applied membranes
- Theory examination
- Practical assessment of applicator with intentional errors that
the candidate Ex-aminer should note and record
- Oral examination and final assessment to recommend the
award of Examiner Certificate

ITAtech Design Guidance For Spray Applied Waterproofing Membranes 43

3 >> Certification / 4 >> Attachments

3.2. Applicator 4. attachments

The applicator will have the necessary experience of application and Under construction.
can demonstrate his technical knowledge and practical ability.

The assessment of membrane applicators will cover the following

areas:
- Theory examination. This may be written but is preferably done
verbally by the Examiner.
- Practical assessment. The Examiner will observe all stages of
a sprayed mem-brane application and shall ask the application
questions related to critical pro-cesses, equipment and spraying
operation and health, safety and environment.
- Overall assessment as to whether a Certificate should be
awarded.
Training is not part of the scheme, though examiners may run their
own training course. In this case the training and the assessment will
have to be clearly separated.

44 ITAtech Activity Group Lining and Waterproofing

ITAtech Design Guidance For Spray Applied
Waterproofing Membranes

Appendix C:
Generic Detail Drawings

ITAtech Design Guidance For Spray Applied Waterproofing Membranes 45

Note 1:
The receiving substrate shall be appropriate for application of the spray applied waterproofing
membrane. It shall be treated (smoothing layer and/or primer) prior to membrane application
according to the membrane supplier’s instructions and/or to the Work Specification.
Note 2:
This drawing and all included details are only illustrative. Detailed design shall be done by the
design engineer based on the specific project requirements.
Note 3:
Dimpled sheet strips shall be properly installed onto the primary concrete lining (typically in
the tunnel crown and bench) at regular distances, for example 3 m, and be connected to
the groundwater drainage system (see Detail2). They can be interconnected et the tunnel
drainage level with a regulating layer of sprayed concrete (not shown in Detail 1 and 2) prior
to membrane application.

46 ITAtech Activity Group Lining and Waterproofing

Note 1:
The receiving substrate shall be appropriate for application of the spray applied waterproofing
membrane. It shall be treated (smoothing layer and/or primer) prior to membrane application
according to the membrane supplier’s instructions and/or to the Work Specification.
Note 2:
This drawing and all included details are only illustrative. Detailed design shall be done by the
design engineer based on the specific project requirements.
Note 3:
The design of construction and expansion (dilatation) joints depends on the type of spray
applied membrane in use on the project requirements. It shall comply with the specific project
requirements and the recommendations of the membrane’s supplier.

ITAtech Design Guidance For Spray Applied Waterproofing Membranes 47

Note 1:
The receiving substrate shall be appropriate for application of the spray applied waterproofing
membrane. It shall be treated (smoothing layer and/or primer) prior to membrane application
according to the membrane supplier’s instructions and/or to the Work Specification.
Note 2:
This drawing and all included details are only illustrative. Detailed design shall be done by the
design engineer based on the specific project requirements.

48 ITAtech Activity Group Lining and Waterproofing

Note 1:
The receiving substrate shall be appropriate for application of the spray applied waterproofing
membrane. It shall be treated (smoothing layer and/or primer) prior to membrane application
according to the membrane supplier’s instructions and/or to the Work Specification.
Note 2:
This drawing and all included details are only illustrative. Detailed design shall be done by the
design engineer based on the specific project requirements.
Note 3:
Waterproofing of the interface between sprayed concrete and segmental linings depends on
the design requirements of the project, including water pressure and anticipated differential
settlement. A combination of spray applied waterproofing membrane and sheet membrane
and/or other waterproofing materials may be required.
ITAtech Design Guidance For Spray Applied Waterproofing Membranes 49
Note 1:
The receiving substrate shall be appropriate for application of the spray applied waterproofing membrane. It shall be treated (smoothing layer
and/or primer) prior to membrane application according to the membrane supplier’s instructions and/or to the Work Specification.
Note 2:
Overlapping shall be done according to supplier’s instructions. the existing membrane shall be properly cleaned and inspected prior to
application of the new membrane to build and overlap, according to supplier’s instructions.
Note 3:
This drawing and all included details are only illustrative. Detailed design shall be done by the design engineer based on the specific project
requirements.

50 ITAtech Activity Group Lining and Waterproofing

Note 1:
The receiving substrate shall be appropriate for application of the spray applied waterproofing membrane. It shall be treated (smoothing layer
and/or primer) prior to membrane application according to the membrane supplier’s instructions and/or to the Work Specification.
Note 2:
Overlapping shall be done according to supplier’s instructions. the existing membrane shall be properly cleaned and inspected prior to
application of the new membrane to build and overlap, according to supplier’s instructions.
Note 3:
This drawing and all included details are only illustrative. Detailed design shall be done by the design engineer based on the specific project
requirements.

ITAtech Design Guidance For Spray Applied Waterproofing Membranes 51

Note 1:
The receiving substrate shall be appropriate for application of the spray applied waterproofing membrane. It shall be treated (smoothing layer
and/or primer) prior to membrane application according to the membrane supplier’s instructions and/or to the Work Specification.
Note 2:
The spray applied waterproofing membrane shall cover insertions with a min. of 50 mm or according to the membrane supplier’s instructions.
If possible, insertions shall be installed after the membrane application, the membrane shall be re-applied onto the interfaces with insertions.
Note 3:
This drawing and all included details are only illustrative. Detailed design shall be done by the design engineer based on the specific project
requirements.

52 ITAtech Activity Group Lining and Waterproofing

ITAtech Design Guidance For Spray Applied
Waterproofing Membranes

Appendix D:
Case Studies

ITAtech Design Guidance For Spray Applied Waterproofing Membranes 53

>> Table of contents

1. Giswil Road Escape Tunnel, Switzerland .......................... 55

2. Gevingåsen Railway Tunnel, Norway .................................... 56

3. Toronto Transit Shepard Line Extension, Canada ......... 57

4. MTRC West Island Extension C708, Hong Kong ................. 58

5. Buenos Aires Metro Line B Extension, Argentina ........... 59

6. Croydon Cable Tunnel, United Kingdom ............................ 60

7. Tesimo Tunnel, Italy ..................................................................... 61

8. Special Underground Project, India ................................... 62

54 ITAtech Activity Group Lining and Waterproofing

1 >> Giswil road escape tunnel, switzerland

1.1. Project details

7- 
Application of MASTERSEAL 345 (min. 3 mm) onto the
The 2,066 m long Giswil road tunnel in the Canton of Obwalden,
substrate in the invert (70-80 m2/h)
Switzerland, was opened in 2004. It provides a bypass for the town
of Giswil. The project consists of a two-lane road tunnel and an 8- Installation of the secondary lining in the invert one day after
emergency escape tunnel running approx. 20 m parallel to the main membrane application.
tunnel. Connections between the main tunnel and the emergency
Quality control was done mainly by measuring the membrane curing
escape tunnel are provided every 300 m. The tunnel was excavated
status and achieved membrane thickness, as well as thorough
in rock by the drilland- blast method. The portal zones were built
inspection of the cured membrane surface before application of the
as cut-and-cover sections. The emergency escape tunnel was
secondary (inner) concrete layer. Furthermore, groundwater pressure
excavated by a 4 m diameter hard-rock TBM and partly by the
has been monitored since 2004.
drill-and-blast method. The project owner is the Canton of Obwalden
and the total project cost is approx. CHF 133 million.
1.4. Project benefits

1.2. Design approach adopted The related project benefits include:

The spray applied waterproofing membrane MASTERSEAL 345 • No water ingress since installation in 2004.
was installed as a fully-tanked (non-drained) waterproofing system •C
 ontinuous membrane application with full membrane
in between two sprayed concrete linings in the southern part of the coverage.
emergency escape tunnel (area of approx. 2,000 m2).
•C
 ompatibility with other sealing systems.
•C
 ontinuous waterproofing from the bored tunnel to the cut-
1.3. Application approach and control
and-cover tunnel section.
MASTERSEAL 345 application was done by manual handheld •F
 aster installation of the waterproofing system and the inner
nozzle, as described in the following: sprayed concrete lining.
1- Treatment of water seepages through the substrate with PU
•R
 educed construction time.
and acrylic injection
2- Cleaning of the substrate with water and air
3- Application of MASTERSEAL 345 (min. 3 mm) on the tunnel
bench and crown (70-80 m2/h)
4- 
Installation of the secondary (inner) lining one day after
membrane application
5- Installation of the primary lining in the invert
6- Cleaning of the substrate in the invert

ITAtech Design Guidance For Spray Applied Waterproofing Membranes 55

2 >> Gevingåsen railway tunnel, norway

2.1. Project details 2.3. Application approach and control

The Gevingåsen single track horseshoe-shaped railway tunnel MASTERSEAL 345 application was done by manual handheld
is 4 km long and was built between Hommelvik and Hell on the nozzle, as described below:
Nordland Line between the city Trondheim and the Trondheim 1- Installation of a smoothening layer onto the primary sprayed
airport. Prevailing ground conditions were hard rock with mica and concrete lining (substrate)
green schist. Tunnel excavation was done by drill‐and‐blast method
(30-100 m overburden). The tunnel was put into operation by the 2- Temporary drainage of seepage spots
Norwegian National Rail Administration in 2011. It reduces travel 3- Application of MASTERSEAL 345 in one pass
time by five minutes and has contributed to increased capacity from
5.4 to 8 trains per hour. Tunnel costs are about NOK 635 million 4- 
Inspection and eventual treatment of water seepage and
(approx. EUR 86 million). This was the first full-scale use of a spray membrane application
applied waterproofing system in a Nordic country. 5- Installation of the secondary (inner) sprayed concrete lining
onto the membrane.

2.2. Design approach adopted Quality control was done mainly by measuring the membrane curing
status, achieved membrane thickness and coverage. Systematic
The tunnel lining consists of permanent sprayed concrete with a inspection of the cured membrane surface was carried out before
waterproofing layer in‐between two concrete layers. Any groundwater application of the secondary (inner) concrete lining.
approaching the finished tunnel is diverted through to the tunnel invert
and channelled to a main pumping station. Following its successful
application to a short section in 2009 and tests at SINTEF the spray 2.4. Project benefits
applied waterproofing membrane MASTERSEAL 345 was installed
The related project benefits include:
with a thickness of 3 mm in the central part of the tunnel (45,000 m2).
Conventional waterproofing with PE-Foam insulation and drainage • Faster installation of the waterproofing system, with reduced
shield was used in the portal zones and in two zones with very high construction time.
water ingress. • Reduced maintenance over service lifetime.
• Simple routine inspection of the final lining.
• No use of inflammable materials (no PE-Foam insulation), where
the membrane was applied.
• Longer service lifetime than the originally tendered technical
solution.

56 ITAtech Activity Group Lining and Waterproofing

3 >> Toronto transit shepard line extension, canada

The two layers of membrane were in contrasting colours: the first

in orange, the second in white/grey. This approach allowed the
thickness of the membrane to be controlled and allowed for easier
quality control checking of the application.
Coverage was checked using a combination of visual inspection and
frequent depth gauge and patch testing.

3.4. Project benefits

Using Tamseal 800 spray applied waterproofing membrane for the

cross-passages allowed the project to install the membrane quickly
and easily without the need for additional specialist equipment or
the manual handling involved in cutting, welding and testing a sheet
3.1. Project details
membrane to changing profiles.
The Sheppard Line Extension of the Toronto Light Rail project, that • Bonded membrane solution with drainage.
had been cancelled by the Mayor is 2007 earned a reprieve in 2012
• Membrane installed using basic equipment already available
and work on the project recommenced to increase the scope of
on site.
Toronto’s public transport system. The project is being constructed
by the McNally/Kiewit/Aecon JV (MKA JV). It was decided to use • Cross passages easily integrated into the rest of the tunnel
Tamseal 800 spray applied waterproofing membranes in the cross system.
passages. • No requirement for complex secondary lining shutters.
• Easier connection details to running tunnels.
3.2. Design approach adopted

The project designers Hatch Mott MacDonald (HMM) have opted to

use Tamseal 800 spray applied waterproofing membrane in conjunction
with a drainage fleece. The membrane will bond to the primary lining, but
should water breach the membrane in any location it will travel through
the fleece applied to the back into the drainage system.

3.3. Application approach and control

The surface of the primary lining was prepared using a regulating

layer: giving a surface finish without fibres and large holes. The
membrane was then applied in two layers using hand application
with rollers/brushes.

ITAtech Design Guidance For Spray Applied Waterproofing Membranes 57

4 >> MTRC west island extension c708, hong kong

4.3. Application approach and control

TamSeal 800 was spray applied using dry shotcreting equipment.

It was applied in one layer, approximately 3mm thick using hand
spraying techniques. The sheet membrane strips had been previously
installed and the membrane was applied directly over the top. A
10mm thick layer of TamCrete TopShot had been applied to the
surface of the sprayed concrete between the geotextile strips to give
a suitably smooth substrate on which to apply the TamSeal 800 in
one single pass, ensuring approximately 3mm membrane thickness.
The membrane was checked using depth gauges and test patches
as well as visual inspection to ensure the membrane was complete.

4.4. Project benefits

4.1. Project details
Using Tamseal 800 spray applied waterproofing membrane allowed
The Mass Transit Railway Project in Hong Kong is being extended. the caverns to be constructed more quickly and efficiently than if a
On Contract 708, the West Island Extension TamSeal 800 was used sheet membrane solution had been chosen. The secondary lining
to waterproof magazine caverns where explosives could be stored installed inside the membrane was permanent sprayed concrete,
for use in the rest of the project. The material was used in several using the bond of the waterproofing to the substrate to give a suitable
locations across the project, by both Gammon Construction and by firm surface without the need to install mesh and frames to support
Super Rich Engineering. the lining as might have been the case using a sheet membrane. This
approach also avoided the need to create bespoke shuttering to cast
a secondary lining in-situ.
4.2. Design approach adopted
• Effective waterproofing system, keeping the contents of the
The design approach adopted by the Arup/Atkins Joint Venture was caverns safe and dry.
to use TamSeal double sided geotextile fleece strips. This allowed
• Quick and easy application of the waterproofing system without
a systematic dissipation of water to a drainage system, reducing
the need to bring in additional teams and equipment.
pressures onto the membrane and the secondary lining.
The use the Tamseal 800 EVA co-polymer membrane system that • Sprayed concrete secondary lining applied over the membrane,
allows double bonding in the areas where the sheet strips are not saving further time and money.
applied, allows quick and easy application of the waterproofing and
sprayed concrete secondary lining.

58 ITAtech Activity Group Lining and Waterproofing

5 >> Buenos aires metro line b extension, argentina

5.1. Project details 5.3. Application approach and control

The extension to Buenos Aires Metro Line B includes additional The Integritank HF system comprises a primer followed by two coats
stations and terminates in a parking garage and workshop for the of membrane, each 1.5mm thick in contrasting colours – yellow
metro trains. The new garage cavern is 18m diameter at its widest then white - sprayed by hand for maximum quality control. Each
and 11m high, of NATM construction, with primary and secondary cured typically in 30 minutes, and wet film thickness was measured
linings of sprayed concrete, and is 10–15m below the water table constantly. To confirm that effective high performance waterproofing
in permeable ground. The workshop structure utilised a similar had been achieved the membrane was tested qualitatively after
construction method and is about 12m wide and 6.4m high, and installation by electrical integrity spark testing that provided reliable
around 20m below the water table. The requirement from the client, results quickly and without damage
Sbase, was for a higher level of watertightness than achieved in to the membrane (see photo, right, above). 20,000m2 of Integritank
previous projects. HF membrane was installed, meeting the demands of both the
contractor for rapid installation and the client’s for high watertightness.
5.2. Design approach adopted
5.4. Project benefits
The main contractor Benito Roggio required a sprayed waterproofing
membrane that could be tested in-situ, after it had been installed but Integritank HF’s unique project benefits included:
before the secondary lining was applied, to prove that a continuous,
•N
 on-destructive testing of the waterproofing membrane
defect free waterproofing installation had been achieved.
enabled confirmation of its 100% integrity prior to secondary
Sbase were adamant that the workshop cavern in particular needed lining installation.
to be as dry as possible. The workshop cavern was also the deepest
structure on the site and subject to the most water ingress during •R
 apid application and cure of the membrane, assisting in
construction, with the ground remaining wet despite dewatering. shortening the construction programme: each coat cured in 30
High adhesion to both the concrete linings was also required, to minutes.
prevent tracking of water. Benito Roggio selected the Integritank •E
 xcellent durability and adhesion: Integritank HF minimized
HF sprayed membrane from Stirling Lloyd, which accommodates potential physical damage to the waterproofing from other site
moisture within the concrete and has a cure unaffected by humidity, activities.
and a local specialist applicator was trained by Stirling Lloyd to install
the system.

ITAtech Design Guidance For Spray Applied Waterproofing Membranes 59

6 >> Croydon cable tunnel, united kingdom

6.1. Project details 6.4. Project benefits

As part of the expansion its high voltage power distribution in SE By using the Integritank HF spray-applied system, Morgan Tunnelling
England, National Grid plc contracted Morgan Tunnelling to build were able to construct a tunnel not only with effective long term
a 4m diameter cable tunnel to carry heavy duty power cables. protection to the assets within, but also to achieve it in a very
Construction was by TBM, with the linings of the front and back cost-effective manner with both decreased build time and cost.
shunts being formed by primary and secondary sprayed concrete Additionally, Integritank HF’s tolerance of difficult site and weather
with an effective waterproofing membrane sandwiched between the conditions enabled application in February in a northern winter
two layers. when the temperature varied between 0°C and 4°C, which would
preclude the application of membranes based on other resins. The
use of a liquid sprayed system that could follow the contours of the
6.2. Design approach adopted tunnel meant no time consuming and costly scaffolding or detailing
The chosen waterproofing system needed to be capable of forming associated with sheet membranes was necessary.
a tenacious bond to both layers of sprayed concrete as well as being Integritank HF’s unique project benefits included:
tough enough to withstand the spray application of the second • Non-destructive testing of the waterproofing membrane
concrete lining. Following extensive testing and evaluation, Morgan enabled confirmation of its 100% integrity prior to secondary
Tunnelling selected Stirling Lloyd’s Integritank HF, a spray-applied, lining installation.
seamless methacrylate resin based membrane system.
• Rapid application and cure of the membrane, assisting in
shortening the construction programme.
6.3. Application approach and control
• High durability and adhesion: Integritank HF minimized potential
The application, by Stirling Lloyd Construction Ltd, consisted of physical damage to the waterproofing from other site activities.
Integritank HF Primer followed by two coats of Integritank HF
membrane. Two coats aid quality control, and the thickness of each
coat was checked every 2 m2 using wet film techniques. The final
quality check was the use of high voltage holiday detection testing to
confirm the 100% integrity of the waterproofing.

60 ITAtech Activity Group Lining and Waterproofing

7 >> Tesimo tunnel, italy

7.1. Project details 7.3. Application approach and control

The Tesimo tunnel is situated on the Italian provincial road which The application of shotcrete has been designed to smooth the
leads from Lana to Tesimo (in the province of Bolzano). surface but also to temporarily stop the residual water infiltration still
The tunnel was built about ten years ago in basaltic rock formations present in summer time. After checking the regularity of the surface
that were strongly fractured, and with low over-burden, which have of shotcrete, an application of the membrane was carried out. Since
led every year during the winter season, to water infiltrations and thus an application of this type of material had never been performed, a
ice formation on the road. teaching course by our MAPEI UTT technical staff was organized for
the company workers.
The section of the tunnel is quite narrow and crossed by heavy daily
traffic. It was therefore decided to intervene with a waterproofing The control of the thickness of the membrane was performed in two
treatment without interfering with that section of the tunnel. ways:
• By checking the coverage area using each Mapelastic TU
System packing.
7.2. Design approach adopted
• By measuring with a special feeler gauge the thickness of the
As the surface of the tunnel appeared highly irregular with open applied material on each square meter
fractures in the rock up to several centimeter, it was necessary to
provide a uniform layer of structural shotcrete to the arch, in order to
provide a sufficiently regular and continuous surface for the sprayed 7.4. Project benefits
membrane.
The intervention allowed to waterproof the tunnel and also to prepare
As it was not possible to modify the section of the tunnel, the
an appropriate surface for the application of subsequent coatings to
protection of the membrane was insured by applying a layer of
improve the brightness, obtaining the following advantages:
structural premixed mortar of 3 cm.
• No traffic interruption.
• Minimum variation of the tunnel width.

ITAtech Design Guidance For Spray Applied Waterproofing Membranes 61

8 >> Special underground project, india

8.1. Project details 8.3. Application approach and control

An important project is underway in India: the construction of a tunnel The application of shotcrete has the purpose not only of leveling the
for a special purpose. The tunnel has been mined inside terrain surface but also temporarily stopping the residual waters present
with very different soil characteristics, ranging from loose earth to during summertime. After testing the shotcrete surface to verify the
hard rock. The excavation process was determined not only by the smoothness, the membrane is applied.
ground conditions but also by the presence of ground water which A 24-hour on-site UTT MAPEI technician has been assigned to
had to be managed to allow for fast excavation. provide client support as needed.
The tunnel must be completely dry before it can be used, so the • By verifying the area covered with the use of each package of
decision was made to use the waterproofing MAPELASTIC TU MAPELASTIC TU SYSTEM.
SYSTEM spray-applied membrane in order to ensure the efficacy of
the waterproofing system. • By measuring with the proper feeler gauge the width of the
material applied per square meter.
The whole project consists of a tunnel of 10 meters in diameter, 2.4
km long. Where there are water inflows present which are too big to be
managed with shotcrete, a pre-treatment of the section of the
tunnel is carried out with specific methods and materials, in order to
8.2. Design approach adopted correctly apply MAPELASTIC TU SYSTEM.
The design of the tunnel has this typical configuration:
• Steel ribs. 8.4. Project benefits
• Wet shotcrete The application of MAPELASTIC TU SYSTEM allows the client to
• Final wet shotcrete to ensure an even layer have a tunnel with a very high waterproofing characteristic, with an
extremely fast application, and no requirement of heavy equipment
•S
 pray-applied waterproofing with the MAPELASTIC TU to install a standard waterproofing membrane.
SYSTEM
The whole waterproofing method suggested to the client gives
•T
 emporary shotcrete layer, 50 mm thick, to protect the reliable results onsite even in difficult ground conditions.
waterproofing system as the final lining will be made only after
total completion of the work.
•F
 inal cast in situ concrete lining, in some sections reinforced
with steel rebar.

62 ITAtech Activity Group Lining and Waterproofing

ITAtech Design Guidance For Spray Applied Waterproofing Membranes 63
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