Inj Presentation BASF Workshop 2012

BASF Injection Technology for Underground
Construction & Mining 2012

Karl Gunnar Holter
Technical Manager Injection and Waterproofing
MEYCO Underground Construction Europe
Hans Olav Hognestad
Technical Manager Injection
MEYCO Underground Construction Global
Uwe Wyink
Technical Manager Coal Mining
MEYCO Underground Construction Gobal
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2
Contents of the presentation
Injection in underground construction

 overview on types of problems to be solved
 overview on available BASF UGC injection technologies
 Rheocem microcements
 Product properties
 Pre-injection method
 Mineral grout: Colloidal silica MEYCO MP 320
 Product properties
 Advantages
 Field of use
 Polyurethanes (PU) and urea silicates
 Types of BASF UGC PUs
 Field of use
 Acrylates
 Types of BASF UGC acrylates
 Field of use
3
The main areas of use for injections in
underground construction and mining
Water ingress reduction and

Repair injections in tunnel lining
ground consolidation
 Pre- and post-injections  Repair of masonry and brickwork lining
 Injection systems, which set relatively slow: 10  Crack injections in concrete lining
minutes up to several hours  Precise and detailed approach
 Ordinary Portland cement  Small scale work, labour intensive
 Microcement systems
 Mineral gel, colloidal silica
Rapid water stop injections Rapid ground consolidation
 Water ingress is too big for cementitious  Ground improvement required within very short
injections (grout is flushed away before setting) time (a few minutes)
 Unexpected and often uncontrolled situations  When a collapse situation is imminent and very
 Rapid reacting and foaming resins often high mechanical strength can immediately
required resolve the situation
 Coal mining
4
Four main categories of injection
technologies to solve problems
Cementitious grouting systems Mineral grouts

 Ordinary Portland cements  Colloidal silica
Polyurethanes and urea silicates Acrylates

 1-component systems  Sophisticated 2-component systems
(hydroreactive)  Very low viscosity
 2-component systems with taylored  High reactivity
properties
 Taylored properties
 Foaming and non-foaming resins
5
Understanding the problem, selecting
the right injection technology
Elimination of small drips or

massive water inflow ?
6
7
Understanding the problem
Ground improvement injections
8
Ground consolidation and water
ingress reduction in underground
constructions
9
Ground consolidation and water
ingress reduction
 Always try with cementitous systems

 Because they are the cheapest
 They normally have a number of other advantages (simple to use, logistics and
availablity, environmentally friendly)
 Plan to use a cost-effective method
 Pre-injections when possible
 Combine with post-injection for optimum result
 Focus on total cost-effectiveness
 Technical performance that is possible to achieve
 Time
 Total cost
10
Cementitous grouts
Main available types
 Ordinary Portland Cements (OPC)

 Locally manufactured normal construction cements
 Normally relatively coarse grained
 „Conventional“ microcements
 Cements especially manufactured with fine grain properties
 Available also in very fine grained qualities – down to a d95 of 6μm
 BASF UGC microcements, the RHEOCEM system

 A „tunnelling injection cement“ which is cost-effective (setting time, performance in
water temperatures 1-40 oC)
 Available in three grades (650, 800 and 900), with d95 ranging from 16 μm to 9 μm
11
Size matters!
12
Particle sizes
Fine cement RHEOCEM

Surface Area = High (if you add fine fillers) microcement
D95 = 50micron e.g. Surface Area = High
D95 = 10micron e.g.
13
An important cost-benefit with
RHEOCEM microcements:
The whole injected volume hardens

fast 14
RHEOCEM
microcements
 RHEOCEM is a system.
 To get the best performance, you should

always use a RHEOBUILD dispersing agent
together with RHEOCEM
 The best suited is RHEOBUILD 2000 PF,

which is also suited for ordinary cements
 We have done many tests, and RHEOBUILD

2000 PF with a dosage of 1.5 - 2.0 % of
cement weight, provides the best result.
Rock injection
Colloidal silica MEYCO MP 320
Ultrafine - RHEOCEM 900 Injection into

cracks =
Ultrafine – RHEOCEM 800 3 x cement
particle size
Microfine - RHEOCEM 650
Normal fine cement
0.001 0.01 0.1 1 10 100
Urban tunneling requires injections for towards 0,02 mm cracks

16
Injection material to suit soils
S I L T S A N D G R A V E L
Fine Medium Coarse Fine Medium Coarse Fine Medium Coarse
0.002 0.006 0.02 0.06 0.2 0.6 2 6 20 60

100
90
80
Percentage Passing
70
60
50
40
30
20
10
0
0.001 0.01 0.1 1 10 100
Grain Size (mm)
Mineral Grouts: MEYCO MP 320 Colloidal silica
Microfine cements: RHEOCEM 650, 800 and 900
Cementitious injection: OPC

17
Cementitous injections,
basic equipment setup
+ Water (w/c 1.0) + 1.5% RHEOBUILD 2000 PF
MIXER PUMP
Packer
AGITATOR TANK
18
Injection plant
Häny compact unit
Can be used for all types of injection cements
as well as colloidal silica
19
Modern equipment for large scale
pre-injections: new injection rig
20
RHEOCEM in big bags: Logistics
for large scale pre-injections
21
NEW! Controlled accelerated setting of
microcement
The precise dosage of additives (accelerators) to the microcement, through a

separate additive pump, which runs as a „slave“ to the main pump
COLLOIDAL
AGITATOR
MIXER
TO GROUTING LOCATION
MAIN GROUT PUMP
INTERFACE
ADDITIVE
PUMP
LIQUID MIXING DEVICE (Y-PIECE)

ACCELERATOR
22
Cement based injections; adding
additives to manipulate grout properties
Problem : The injection material flows away
Alcali
SA 160free
accelerator
Rheocem
23
Injection with unaccelerated grout
1. Grout can flow far away

2. Possibility of backflow in unfavourable
situations
24
Injection with controlled accelerator dosage
1. If no counterpressure – start dosing

the accelerator
2. Limits uncontrolled flow of grout
3. Can stop backflow of grout into the
tunnel
25
Colloidal silica for ground
consolidation and water ingress
reduction
26
Colloidal Silica Technology
 Colloidal silica gel is a “mineral grout”, and is not a

chemical grout
Silica gel (hard aggregates)  It is a stable liquid containing single, sub-
microscopic particles of silica oxide
 To make it gel, a weak solution of salt water is
mixed prior to pumping. The more salt water is
Precipitated silica (grape clusters) added, the faster the gel time
 It is environmentally friendly and durable, as it is
simply composed of quartz sand, water and salt!
Silica fume (chain-like)  Having the same consistency as water, it
penetrates sand and fine fissures very easily
 It is extremely user-friendly, as standard equipment
can be used and cleaned with water
Colloidal silica (primary particles)
27
Colloidal silica
Definition of a colloid
 Small insoluble, non-diffusible
particles
 Larger than molecules
 Small enough to remain
suspended in a fluid medium
without settling
28
Viscosity over time
1000
800
Viscosity (cP)
600
Collision
400
start
200
0 10 20 30 40
Time (min)
29
Compressive strength over
time
Ongoing reinforcement
Uniaxial compressive strength
140
120
100
(N/cm2)
80
60
40
20 Coalescence start
0
0 100 200 300 400 500 600 700 800 900 1000
Time (days)
30
Colloidal silica:
Strength development over time
1200
Uniaxial compressive strength
1000 Laboratory samples

800 7:1 with sand
(kPa)
7:1 pure gel

600
9:1 with sand
400 9:1 pure gel
200
0
0 10 20 30
Time (days)
Curing conditions: 20 oC,

100% humidity
31
Colloidal silica, MEYCO MP 320:
Strength development over time
Samples from in-situ

pre-injected sand
(ahead of the tunnel 0.7
face), Portugal
MPa
Testing of uniaxial
compressive strength 0.4
MPa
Results from lab, show the
same level of strength
0.45
MPa 32
Colloidal silica for injections from BASF
- MEYCO MP 320 group of products
 MEYCO MP 320, 40% SiO2 content

 MEYCO MP 320T, 30% SiO2 content
 MEYCO MP 325, 15% SiO2 content
 All use the same accelerator, 10% NaCl in water
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Main properties colloidal silica
 pH <11
 Content: water, SiO2 and Na2O < 0,7. (Water-glass has > 7)
 Other applications: Water treatment, clarification of wine and juice,
coatings, polishing of silica wafers
 Silica sols are Reinheitsgebot approved in Germany and used in
the beer production
 Not classified product, see the MSDS
 Catalyst (accelerator) : Salt NaCl and water, in the grout mixture,
which has a lower salt concentration than the North Sea!!
 Not classified product, see the MSDS
34
Colloidal silica : a better choice than
silicate (waterglass) gel
Typical parameters for silicate gel:

 Viscosity 180 m•Pas
 Very brittle gel
 Shrinkage of the gel
 Liquid separation of the gel
 Very high gelation speed, difficult to control gelling
 High pH ~13 - 14 pH
 Impurities (chlorides, iron etc.)
 Soluble in water - only for temporary use
 Environmentally unsafe due to the leaking of alkali into the ground water
 Restricted use in many cases due to the environment
35
Colloidal silica injection
Controllable gel times
160
150
140
Gel time (minutes)
120
100
80
60
56
40
31
20
18
11
0
10 15 20 25 30
Values at 8°C
Accelerator % by volume
36
Colloidal silica
Where to use?
 Consolidation of sand, silt and weak rock where microcement can not
penetrate
 As “fine” injection after being first injected with microcement to take the
last drops of water
 Crosspassages in TBM tunnels
 TBM breakouts into shafts
 Slope stabilisation
 Open pit excavation, preventing groundwater lowering
37
Colloidal silica: stable gel
No shrinkage in humid conditions
Sand that has been injected with MEYCO MP 320.

The samples have been kept in water for more than 5 years and
show no visible shrinkage.
38
References colloidal silica
39
MEYCO MP 320 Colloidal Silica
Consolidation of weak sandstone in Portugal
40
Maneri Bhali hydropower, India
Pre-injection for water ingress reduction and
ground stabilisation
Injection of RHEOCEM
650 and MEYCO MP 320
colloidal silica
41
Colloidal silica pre-injection :
Törnskogstunneln, Stockholm
 Systematic pre-injection with

MEYCO MP 320 in a twin tube
highway tunnel
 A total of 335 tons injected over

500 linear meters
 One could reduce the need of

drainage mats by 80% in
comparison with injecting
microcement
42
MEYCO MP 320 colloidal silica:
High speed rail tunnel Bologna
Stabilisation of silty sand for

the excavation of cross-
passages between the main
tubes
Contractor :
San Ruffilio S.c.r.l.
43
MEYCO MP 320
Limmerick, Ireland
Soft gravely
clay
Peat
Perforated steel
Soft silty clay injection pipes installed
6m concrete into sand. Length ~2m
segment shaft
Soft gravely TBM advance
clay after injecting
Loose,silty MP 320
sand
Sandy gravel
Gravel and
boulders
Limestone Injection of MP 320 colloidal silica from the

shaft using a 1 component pump 44
A few words on
Modern pre-injection in
underground construction
45
What is pre-injection?
Pre-injection
In front of the tunnel face Tunnel
Post-injection
Behind the tunnel face
Tunnel
46
Pre-injection
Typical length: 15 to 30 m
Typical spacing: 1 to 2 m
Pre-injection is far more economical than post injection!

47
Pre-injection is often a
systematic approach
5m
~9m
5m
~ 15 m ~6m
48
Why pre-inject?
 Safety
 Environment
 Cost
49
Water ingress in tunnels and
mines
Safety
One of the largest
problems in tunnels is
uncontrolled water ingress.
Two of the biggest risks
are
Immediate flooding
 Ground collapse
associated with water
ingress
50
Water ingress in tunnels and
mines
Environment
 Environmental
concerns is another
issue
 Contaminated water
has to be managed
 Lowering of ground-
water has to be
prevented in most
areas
51
Water ingress in
Water in tunnels tunnels and
mines
Cost
 Pumping water is huge
cost (e.g. sub sea tunnels)
 Reduced tunnel
production
 Can put a stop on work for
shorter or longer periods
of time
 Right focus: Not kg price,
but time consumption
52
Relation between
pre-injection and post-injection
 Experience shows that
 Post-injection alone is often useless and very costly

 Pre-injection
Pre can solve almost all problems
 Pre-injection
Pre target of 100% sealing Not realistic
 Post-injection as a supplement is effective
 An optimised use of pre- and post-injection in

combination is a good approach
53
Drilling for injections ahead of the
TBM
A systematic method to stop water ingress
Sewer tunnels, Oslo, 1980

54
Cost-effective pre-injections ahead of a TBM:
Water ingress reduction and ground
improvement in difficult rock
Arrowhead Tunnels Project – San Bernardino, CA

55
Pre-injections ahead of TBM:
Drilling patterns
1,5° 4° Face
Face
Arrowhead Tunnels Project – San Bernardino, CA 56

Some recent references
on pre-injection
57
Lofast road tunnel, Norway Groundwater 3 oC and with high
pressure, open water bearing joints
Pre-injection with accelerated microcement grout for rapid setting in cold water
58
Jong - Asker Norway
Double track rail tunnel
 Hard rock tunnel 110 m²

~ 7200 m
 Maximum allowed leak
in: 4l/min/100 m
 Achieved: less than
1l/min/100m tunnel
 Systematic Pre-injection
with RHEOCEM 800 and
Rapid Hardening OPC
 Consumption per linear
tunnel meter:
 RHEOCEM: 897kg
 OPC: 862kg
59
Oset Drinking water plant -
Oslo
2 Caverns: 136.000 m3
excavated rock volume
Allowed seepage into caverns:
100 l/min
Result: 20 l/min
Consumption of injection
materials:
Local OPC: 820 tons
RHEOCEM 650: 1510 tons
60
Liquid propane storage rock cavern,
Norway
61
Coffee break
62
Rapid ground consolidation
63
 Injection systems, which give high strength within a few minutes

 Typical to use in situations where there is an urgent need for ground
improvement
 Mines in faulted zones or areas with low rock strength
 High rock stress areas
 In tunneling when instable situations makes ground
improvement urgent (e.g. a developing collapse with serious
consequences)
64
Stabilizing of fault zones in coal mines 65
Avoid face collapse in coal mines 66
Stabilizing of soil in tunneling
67
Urgent need for ground improvement
Collapse situations
roof sinking spalling
rib movement floor heaving 68

Injection with chemical grouts
69
BASF injection product families
 MP 35X range = PUR = Polyurethane

 A and B component 100 % organic raw material
 MP 36X range = PUS = Polyureasilicate

 A component non organic raw material
 B component organic material
70
Injections for rapid water
ingress reduction
 Injection systems, which give high volumetric foam expansion in

short time when contact with water occurs
 Typical use in situations where there is an urgent need to eliminate
water ingress points
 Cement-based systems are too slow
 Highly reactive chemical resins
 Reaction speed : down to 20-30 seconds
71
MEYCO urea silicate resins
 Group of products MEYCO MP 36X

 MEYCO MP 364 Flex
 Hard resin for rapid ground improvement
 MEYCO MP 367 Foam
 Foaming resin for void filling and consolidation
72
MEYCO® MP 364 Flex
A B
73
Rapid reacting resin for ground improvement
MEYCO MP 364 Flex
 MEYCO® MP 364 Flex is a two component, solvent-free urea-

silicate injection resin for:
1. Stabilizing coal and strata
2. Consolidation of fractured rock, sand, gravel and coal faces
3. Repair of underwater constructions
4. Repair of concrete cracks
5. Rockbolt grouting (in exceptions, not thixotropic)
6. Sealing against gas and water
75
 Technical data MEYCO® MP 364 Flex

Color Viscosity Density
mPas kg/m3
Component A Colourless 300 1490
Component B Dark brown 150 1180
Testing temp. 23°C
Flow time 90s ± 30s
Setting time 2min30s ± 30s
Foam expansion factor 1 Flash point: A non applicable, B > 200ºC
max. reaction temp. 99°C Mix. ratio A:B: 1:1 by volume (100: 79 by weight)
max. bonding strength 6,3 N/mm²

max. deformation work 1400 Nm
Border time < 5 min
Boarder time: Time needed to reach 1 MPa bonding strength in lab conditions 76
Features and benefits

 MEYCO® MP 364 Flex neither expands its volume with water nor
absorbs water
 Penetrates cracks wider than 0.14 mm
 Shows good adhesion to wet and low friction substrates
 Equally fast reaction in dry or underwater conditions
 Very fast reacting material applied where structural strength and
flexibility is required
 Fire resistant
77
MP 364 Flex
78
 Concrete block trial
79
 MEYCO MP 364 Flex for rockbolt grouting
80
 MEYCO MP 364 Flex for rockbolt grouting
81
Rapid reacting foaming resin for void filling and
MEYCO MP 367 Foam
 MEYCO® MP 367 Foam is a two component, solvent-free urea-

silicate Foam
1. Specifically designed to fill cavities rapidly, consolidate coal and
strata in tunnels and mines
2. Consolidate fractured rock, sand, gravel and coal
3. Stabilize cavities in tunnels
82
Void filling to improve stability
MP 367 Foam
83
Urea silica resins
MEYCO MP 364 Flex, MEYCO MP 367 Foam
Summary of advantages of urea silicate resins

 High bonding strength and or high mechanical strength
 Mechanical properties are reached within a few minutes
 Water resistance
 Temporary and permanent applications
 Suitable for both mining and civil applications
 Low reaction temperature
84
 BASF injection product families
 MP 35X range = PUR = Polyurethane

 A and B component 100 % organic raw material
 MP 36X range = PUS = Polyureasilicate

 A component non organic raw material
 B component organic material
85
Rapid ground consolidation in mining with two
component PU system
MEYCO ® MP 358 SC & GS
 MEYCO MP 358 is a two component, solvent-free polyurethane

injection resin system
1. High performance PU resin system for ground stabilization with
excellent deformation capacity and high compressive strength
2. Specially designed to rapidly consolidate coal and rock strata in
mining and tunneling
3. Consolidate fractured rock, sand, gravel and land-fill materials in
underground constructions and mines
4. Sealing against gas and water (prophylactic)
5. Temporary repair of concrete cracks
86
MEYCO® MP 358 SC & GS
A B
87
Rapid ground consolidation with
foaming high-strength resins
 Consolidation of the face intersection
88
Rapid ground consolidation with
foaming high-strength resins
 Consolidation of the face intersection
89
Polyurethane resins
MEYCO MP 358 SC & GS
Summary of advantages of MP 358 system

 MP 358 was developed as a high performance version, which will
replace MP 357 GS
 One can achieve two different 2-component products with only 3
components rather than 4, easy handling
 Temporary and permanent application
 Suitable for both mining and civil application
 Improved foam structure develops higher bonding and better
deformation capacity
 High rock temperatures don't have an influence on the technical
performance
90
Rapid water ingress reduction
91
Injection for rapid water ingress
reduction
 Injection systems, which give a high volumetric foam expansion in
short time when in contact with water
 Typical use in situations where there is an urgent need to eliminate
water ingress points
 Cement-based systems are too slow
 Highly reactive chemical resins are required
 Reaction speed : down to 20-30 seconds
92
94
95
MEYCO polyurethane resins for
water stopping
 Difficulties to complete water stopping

 Water volume
 Fracture distribution in rock
 Water pressure
 Rock and water temperature
96
MEYCO polyurethane resins for
water stopping
 Group of products MEYCO MP 35X
 MEYCO MP 355 A3 - system

 Two-component classic organic polyurethane
 Volumetric foam expansion in contact with water
 Available in different versions
 Highly adjustable properties with different accelerators
 MEYCO MP 355 1K - system
 1-component hydro reactive organic polyurethane
 Also available in drinking water approved version
97
References rapid water ingress
reduction
98
MEYCO MP 355 A3 THIX FAST injections for
water stopping, Karahnjukar HEP Iceland
 2-component polyurethane
resin, rapid in foaming
 BASF UGC developed a

special version of the 2-
component PU for this type
of problem (MEYCO MP
355 A3 THIX FAST)
 Is a customized technical
solution with support from
CONICA in urgent cases
99
MEYCO MP 355 A3 THIX FAST, 2-component PU,
a combination of injection and drainage
Injection holes
Drainage holes
A B
100
Karahnjukar, Iceland:
Injection set-up on California switch
Drainage hole Injection hole
Injection equipment
California switch
101
MEYCO MP 355 A3, 2-component PU
Water stopping injections

Iran, Seymereh Hydropower
102
MEYCO MP 355 A3, 2-component PU for
refurbishment of masonry lining
Rehabilitation of old
masonry tunnels
Croatian Railroads
103
MEYCO MP 355 1K, 1-component PU
Typical area of use : Water stopping injections
104
Injection equipment
&
site installation
105
Polyurethanes and urea silicates
Equipment setup
 Site installation
flushing hoses
air hose
Place the drums close to the pump

suction hoses
Connect the suction hoses with the pump and place them in the barrel
Connect the flushing hoses with the pump and place them in the proper
barrel.
Be careful not to place them into the wrong barrel
conveying hoses DN 20
Connect the conveying hoses to the pump
Connect the air hose to the pump 106

 Polyurethanes and urea silicates
Two-component pumping systems
Piston pump Gear pump
107
Polyurethane injection
Layout of mixing head for two components
108
Application
Site installation
Select pump position

 Safe and smooth operation with the resin pump should be possible
 Should not to interfere with any other mining activities
 Proximity to the injection location
 Sufficient space for the stockpiling and handling canisters
 Site should be well connected logistically
 Good communication must be possible
 Operating instructions and warnings must be visible
 Emergency equipment, first aid material and personal protective
equipment (PPE) is necessary
109
Pump set up
 Place the storage container close to the pump

 Connect the suction hoses with the pump and place them in
the storage container
 Connect the flushing hoses with the pump and place them in
the storage container
 Be careful not to place them into the wrong barrel
 Connect the conveying hoses to the pump
 Connect the air hose to the pump
110
Set up and injection operation
Check all parts of the equipment

 Is the pump working correctly
 Hoses are connected the right way and are not leaking
 Ball and gate valves are easy to open and close
 Pressure gauges function
 Enough spare parts are available
 Protection cloth and safety equipment is on site
 Injection area is secured
111
 Pump flushing hoses
A B
air hose
A to A
suction hoses
B to B
conveying hoses DN 20
112
Pump
 Connect pump to energy
 Air driven pumps always need enough oil
 Connect pump with the resin storage containers
 Hoses A to the white container, B to the black container
 Pump and container are signed in white and black
113
Checks to be carried out Part 1:

 All controls on the pump are functioning and operating correctly
 The pump is set up a little lower than the chemical pods to assist the
pumps suction
 The pump calibration is checked to ensure component ratios of the
resins is correct i.e. 1 to 1 in most cases
 The nozzle man has spare static mixers in his pocket
 Oil is in the oiler and a spare bottle of rock fluid is available
 The equipment is clean and free from spilled injection material
114
Checks to be carried out Part 2:

 All air hoses are operational
 The resin pumping hoses are not blocked
 The compressed air supply to the longwall face line or any part of the
mine that requires injection operations is adequate for the resin pump to
operate efficiently
 All the needed paper work is available and being filled in as required
 Establish restricted zones and warning signs
 Crew Briefing by the supervisor
115
Mixing tube and mixing elements

 Different densities and viscosities of A and B static mixer
 Injection hose of about 5 m
 The static mixer and other parts may occasionally become clogged
(enough spare parts)
 Stationary injection device with permanent tubes

 mobile hoses of 10 to 15 m in length
116
Hardware maintenance and cleaning
 Avoid contact of A and B out of the borehole

 Always flush with white before one stops pumping
 Portable pumps: clean pump and all hoses with oil
 Stationary pumps: only the mixing head and the mobile hoses have to be
cleaned
117
Health & Safety
118
Handling injection agents
 Synthetic resins may cause environmental and health hazards if not

handled properly
 Storage
 Transportation
 Processing
 BASF MSDS provide all the needed information for the safe handling of
the products
 For a variety of products additional application recommendations can be
found in the method statements
119
Storage
 Canisters and/or containers must be stored in places where they cannot
be damaged
 Avoid damage of the container floors
 Damage of the resin containers by rock fall is to be prevented
 Canisters and/or containers must be placed safely and horizontally
 Always think of the storage temperatures listed in the TDS
120
Transportation
 Canisters and/or the containers must be transported in a way that
definitely rules out damage during the transport
 To prevent them from being damaged or crushed
 Propping or bracing the containers may also help to prevent them from
slipping
121
Processing
 A safe, clean and well-lit work place helps to prevent leakages or
splattering
 Avoid skin contact
 The ground should be free from sharp obstacles
 Enough space should be available
 Canisters should be completely emptied
 Canisters and/or containers containing residual quantities of material
must be closed
 Formation of aerosols must be prevented
 Synthetic resins are not to be sprayed
122
Health and Safety considerations
 The ground underneath the pump should be level

 Potential risks, like unorganized material lying around and/or sharp
edges should be removed
 Work area needs sufficient lighting so that labels, displays and
malfunctions of the pump/grouting device can be seen and noticed
immediately
 Good communication must be given
 UGC International provides Material Safety Data Sheets (MSDS) for all
products
 Always us the appropriate PPE
123
Material Safety Data Sheets (MSDS)

 Detailed information on the respective materials
 Potential hazards are described
 Measures to be taken when handling the material are given
 What is to be done in case of an undesired incident are given
 The information and instructions will only be of benefit as long as the
users/operators are familiar with them
 Crew and/or companies processing the product are usually briefed
 Foreman will inform his staff about potential hazards and about first aid
measures
124
Health & Safety
Introduction
125
Health & Safety
Introduction
Personal protective equipment
126
Body Protection
 Disposable paper overalls have proven
suitable as body protection
 They can be easily worn over the regular
working clothes
 paper overalls do not provide
permanent protection
127
Hand Protection
 Hands are best protected by wearing suitable gloves
 Sufficiently tight and resistant against the individual
components and the synthetic resin
 Manufacturer’s MSDS provides the information on
which type of gloves are best suited
 Rubber gloves are most frequently recommended
 Leather or textile do not provide sufficient protection
128
Eye Protection
 Injected grout can suddenly and unexpectedly
escape from cracks
 Fittings can be faulty
 Eyes must be protected during the injection
 Safety glasses that provide protection against
chemicals are best suited
129
130
Potential hazards and first aid measures

 Skin Contact
 Eye Contact
 Inhaling
 Swallowing
131
Skin Contact
 Skin contact may cause a sensitization (allergic reaction) and irritation of
the skin
 Soaked clothes or shoes must be taken off
 Splatters on the skin are to be dabbed away carefully with a clean piece
of cloth
 Rubbing must be avoided
 Do not use solvents or chemicals to remove the product from the skin
 If large areas of the skin have come in contact with the resin (bigger than
10 cm * 10 cm), medical attention must be sought
132
Eye Contact
 Spatters to the eyes cause strong and painful irritations
 Lasting damage has not been experienced
 The affected eye must be rinsed with running water immediately
 The rinsing must last until the stinging ceases, but at least for 10 minutes
 During the injection operation, a bottle for eye-rinsing fluid must be kept
available at the site of the injection
 Medical attention from an eye specialist must be sought immediately
133
Inhaling
 Aerosols can be inhaled
 Aerosols from isocyanate can irritate the mucous membrane of the nose,
throat and lungs
 This can cause coughing, breathing problems, headaches and in rare
cases allergic reactions and asthma-like attacks
 The affected person must be taken to fresh air immediately
134
Swallowing
 Drinking, eating, chewing tobacco and using snuff are absolutely
forbidden
 If the grout and/or one of its components have been swallowed, medical
attention must be sought as a precaution
 Keep the affected person calm and do not try to encourage him to vomit
 The doctor should be shown the Material Safety Data Sheet of the
swallowed product
 No cases have been reported in which the swallowing of components of
synthetic resin has caused health problems
135
Possible problems during injection and solutions
Blocked hoses, packers, injection lances etc.

 Flush regularly before stopping the injection pump
 Clean complete system carefully after the injection process
Leaks
 Stop and go Injection process
 Additional abutments with sprayed concrete or thin spray-on liners
136
Dealing with blockages and emergency system shutdowns
 At some stage during the pumping process there is the risk that
the system has a problem, this may occur due to any number of
circumstances or reasons. If unsure SHUT DOWN the entire
system by following the steps below:
 Open both component valves back to the tanks
 Shut off the high pressure valves
 Turn off and isolate the pumps compressed air supply
 Notify nozzle man
 Rectify problem
137
Production Schaffhausen, Switzerland
Johannesburg,
South Africa
Shanghai,
China
138
Packaging
139
Packaging
140
Repair tunnel linings with
injections
141
Repair injections in tunnel linings
 Masonry linings
 Joints and backfill of masonry lining
 Leaks
 Mechanical improvement
 Cast-in-place concrete linings

 Repair injections in fine fissures
 Pre-cast concrete segment linings

 Fine fissures in a thin high-strength concrete segment
142
Application methods
Water can flow in

every direction!
before and
during injection
143
Application methods
Water is trapped
within barriers!
144
Application methods
Bleed holes to
release trapped
water during
injection
Packer injection
from opposite end!
Resin replaces
water!
145
Application methods
Small packer injections

• Repair to strengthen, fill, stop water and moisture
• Holes are drilled to place packers
• The packer provides access to the repair location
• The packer choice depends on the job
• The packer size depends on the quantity of material to be pumped
• Where to place them depends on the cause and scale of the problem
146
Size and type matters…
Common packers
147
Application methods
Packer set up example
Angle ~45°
≥D/2
148
Application methods
As most people do
Proper drilling depth What we recommend
149
Application methods
Proper drilling distance

Always start with a narrow distance between the packers
Wide spacing Correct spacing
150
Viscosity matters
Why is viscosity important?

1 2 3 4 4 3 2 1
Crack size 1-2 = > 0mm
Crack size 2-3 = < 0.2mm
Crack size 3-4 = > 0.2mm

Below 0.2 mm only products with a viscosity lower than
200 mPas are applicable
Above 0.2 mm products with more than 200 mPas are
applicable
Above 0.5mm viscosity is insignificant
151
Viscosity of different systems
Products and their viscosity
Water 1 mPas
Acrylate < 200 mPas water based
PU resin > 200 mPas hydrophobic
PU foam > 400 mPas hydrophobic
Epoxy > 200 mPas hydrophobic
152
Find out what you really need?
How to select the right product, design issues
Viscosity can it penetrate the cracks

Hardening system will it work at low/high temperatures
Bonding strength will it adhere with a high enough tensile strength
Setting time can it be adapted to my needs
Elasticity can it elongate, compress, swell
Hydrophobic will it repel water
Hydrophilic will it absorb water
Tack will it stick to wet/dry surfaces
Chemical resistance is it durable under the conditions it’s exposed to
Environment are there any hazards
153
BASF UGC injection systems for
tunnel lining rehabilitations
 Acrylates , all designed for durable properties
 MEYCO MP 308,
 MEYCO MP 301 / 302
 Polyurethanes
 MEYCO MP 350, especially designed for crack injections
 MEYCO MP 355 1K, for temporary water stopping
 MEYCO MP 364 Flex, for structural repair in both dry and
humid conditions
154
References tunnel lining
repair injections
155
Budapest Metro, rehab Line 2:
Acrylate injections behind the concrete
lining
 Create a waterproof zone along

the deteriorated concrete-ground
interface
 Dense grid pattern of holes
 Fixed amount of grout per hole
156
New tunnel linings in need of repair !
Sofia Metro Dublin Port Tunnel

MEYCO MP 308 MEYCO MP 308 / 301
157
The repair of the old brick lining in a
rail tunnel
Limone, Piemonte, Italy
Injection of MEYCO MP 350
158
The main areas of use for injections in
underground construction and mining
Water ingress reduction and

Repair injections in tunnel lining
 Pre- and post-injections  Repair of masonry and brickwork lining
 Injection systems, which set relatively slow: 10  Crack injections in concrete lining
minutes up to several hours  Precise and detailed approach
 Ordinary Portland cement  Small scale work, labour intensive
 Mineral gel, colloidal silica
Rapid water stop injections Rapid ground consolidation
 Water ingress is too much for cementitious  Ground improvement required within very short
injections (grout is flushed away before setting) time (a few minutes)
 Unexpected and often uncontrolled situations  When a collapse situation is imminent and
immediate very high mechanical strength can
 Rapid reacting and foaming resins often resolve the situation
required
 Coal mining
159
The four main categories of injection
technologies to solve problems
Cementitious grouting systems Mineral grouts

 Ordinary Portland cements  Colloidal silica
Polyurethanes and urea silicates Acrylates

 1-component systems  Sophisticated 2-component systems
(hydroreactive)  Very low viscosity
 2-component systems with taylored  High reactivity
properties
 Taylored properties
 Foaming and non-foaming resins
160
Thank you for your attention
161

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Inj Presentation BASF Workshop 2012

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BASF Injection Technology for Underground

Construction & Mining 2012

Injection in underground construction

Water ingress reduction and

Rapid water stop injections Rapid ground consolidation

Cementitious grouting systems Mineral grouts

Polyurethanes and urea silicates Acrylates

Elimination of small drips or

Ground improvement injections

 Always try with cementitous systems

 Ordinary Portland Cements (OPC)

 BASF UGC microcements, the RHEOCEM system

Fine cement RHEOCEM

The whole injected volume hardens

 To get the best performance, you should

 The best suited is RHEOBUILD 2000 PF,

 We have done many tests, and RHEOBUILD

Colloidal silica MEYCO MP 320

Ultrafine - RHEOCEM 900 Injection into

Normal fine cement

0.001 0.01 0.1 1 10 100

Urban tunneling requires injections for towards 0,02 mm cracks

Fine Medium Coarse Fine Medium Coarse Fine Medium Coarse

0.002 0.006 0.02 0.06 0.2 0.6 2 6 20 60

Grain Size (mm)

Mineral Grouts: MEYCO MP 320 Colloidal silica

Microfine cements: RHEOCEM 650, 800 and 900

Cementitious injection: OPC

+ Water (w/c 1.0) + 1.5% RHEOBUILD 2000 PF

The precise dosage of additives (accelerators) to the microcement, through a

MAIN GROUT PUMP

LIQUID MIXING DEVICE (Y-PIECE)

Problem : The injection material flows away

1. Grout can flow far away

1. If no counterpressure – start dosing

 Colloidal silica gel is a “mineral grout”, and is not a

1000 Laboratory samples

7:1 pure gel

Curing conditions: 20 oC,

Samples from in-situ

 MEYCO MP 320, 40% SiO2 content

Typical parameters for silicate gel:

 Crosspassages in TBM tunnels

 TBM breakouts into shafts

 Open pit excavation, preventing groundwater lowering

Sand that has been injected with MEYCO MP 320.

 Systematic pre-injection with

 A total of 335 tons injected over

 One could reduce the need of

Stabilisation of silty sand for

Limestone Injection of MP 320 colloidal silica from the

In front of the tunnel face Tunnel

Behind the tunnel face

Pre-injection is far more economical than post injection!

 Experience shows that

 Post-injection alone is often useless and very costly

 An optimised use of pre- and post-injection in

Sewer tunnels, Oslo, 1980

Arrowhead Tunnels Project – San Bernardino, CA

Arrowhead Tunnels Project – San Bernardino, CA 56

 Hard rock tunnel 110 m²

 Injection systems, which give high strength within a few minutes

roof sinking spalling