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PRODUCT MANUAL
Certificate No 86/1650
CONTENTS
WHAT IS VOLCLAY ? HOW VOLTEX WORKS ACCESSORIES LIMITATIONS INSTALLATION GUIDELINES SECTION 1: UNDERSLAB INSTALLATION 1.1 Substrate Preparation 1.2 Installation 1.3 Pile Caps & Ground Beams 1.4 Slab Penetrations 1.5 Lift Pits 1.6 Edge of Slab, Backfilled Walls SECTION 2: PROPERTY LINE CONSTRUCTION 2.1 Property Line Installation Guidelines 2.2 Metal Sheet Piling 2.3 Earth Formed Shotcrete Retention Wall 2.4 Auger Cast Caisson Walls 2.5 Contiguous and Secant Piling SECTION 3: BACKFILLED WALLS 3.1 Surface Preparation 3.2 Installation 3.3 Wall Penetrations 3.4 Terminations 3.5 Masonry Block Walls SECTION 4: TUNNELS/ EARTH COVERED ROOFS 4.1 Installation SECTION 5: SPECIAL CONDITIONS 5.1 Pre-cast Concrete Plank Installation 5.2 Contaminated Conditions 5.3 Tie-in with Envirosheet Self-Adhering Waterproofing Membrane
WHAT IS VOLCLAY ?
Volclay sodium bentonite is a non-toxic mineral of volcanic origin found exclusively in the Black Hills region of the United States. Volclay is specially processed by CETCO to achieve the highest possible performance for all of our waterproofing products. CETCO also manufacturers Volclay CR, a contaminant resistant bentonite to assure optimum performance in saline or contaminated water. Volclay prevents water intrusion by forming a dense monolithic membrane upon contact with water. The specially processed Volclay expands under confinement, forming an impervious membrane that will be maintained for the life of the structure.
Concrete Needlepunched Geotextile Fibres Woven Geotextile Granular Volclay Sodium Bentonite Nonwoven Geotextile
Voltex forms a continuous mechanical bond to concrete. This bond is created when Voltexs strong geotextile fibres are encapsulated by poured concrete as shown in the illustration.
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DURABILITY The Volclay sodium bentonite in Voltex is uniformly encapsulated between two high-strength woven and nonwoven geotextiles. CETCOs state-of-the-art needlepunching process interlocks the geotextiles, preventing the displacement of bentonite prior to, during, and after installation. The geotextiles provide superior protection from inclement weather and construction related damage, without requiring the use of a protection course. SUPERIOR ADHESION When concrete is poured against Voltex, a tenacious mechanical bond is created with Voltexs high strength geotextile. Independent laboratory testing conducted in accordance with ASTM D-903 (Peel Adhesion to Concrete), yields an average adhesion value of 66.7 N/M. The mechanical bond will hold Voltex in intimate contact with the concrete should any ground settlement occur, thereby preventing water migration between the waterproofing and the concrete. COST EFFECTIVE AND TIME EFFICIENT Voltex is designed to be installed on a properly prepared subground, without the need to pour a working slab. The products inherent flexibility allows for easy installation on irregular surfaces and rough property line forming. Voltex seams are easily overlapped without the need to roll out every small wrinkle or air pocket. Voltex can be installed as soon as the forms are stripped; there is no waiting for the concrete to cure. NSF STANDARD 61 CERTIFIED Voltex and Voltex DS are certified by NSF International to conform with the requirements of NSF Standard 61 Drinking Water System Components Health Effects. Both Voltex and Voltex DS are certified as an external protective barrier material for portable water concrete tanks with a 1,000 gallon capacity or larger.
ACCESSORIES
BENTOSEAL - patented trowel grade sodium bentonite compound used to detail around penetrations, corner transitions and terminations. HYDROBAR TUBES - water soluble plastic tubing filled with bentonite, used at the footing/wall intersection. VOLTEX GRANULES - granular Volclay bentonite used at detail areas that may require additional Volclay protection.
INSTALLATION GUIDELINES
Before installing Voltex/Voltex DS read this installation manual to gain familiarity with specific procedures and applications. For applications not covered in this manual, contact CETCO for specific installation guidelines.
Voltex/Voltex DS is engineered for use under reinforced concrete slabs 150 mm thick or greater on a compacted earth/gravel substrate. Voltex requires a minimum 150 mm thick reinforced concrete slab if installed over a mud slab. Voltex CR bentonite is used in contaminated conditions as determined by a Volclay water sample test. Prior to installing Voltex the substrate must be properly prepared. Complete all required lift pit, sump pit, ground beam and piling work prior to installing Voltex under main slab area. These areas must be correctly tied into the underslab waterproofing to form a monolithic seal.
Voltex
Voltex
Voltex
300mm
Figure 1.2 Extend Voltex a minimum 300 mm beyond slab edge. Install Watersop-RX in joint.
RX101 Waterstop Secured with Revofix Mesh Nailed at 300mm Centres. With a Minimum 75mm Concrete Cover. Slab Second Pour
300 100
1.2 Installation
Install Voltex or Voltex DS over the properly prepared substrate with the dark grey (woven) geotextile side up. Overlap all adjoining edges a minimum of 100 mm and stagger sheet ends a minimum of 300 mm (Figure 1.1). Nail or staple edges together as required to prevent any displacement before and during concrete placement. When the slab is poured in sections, Voltex should extend a minimum 300 mm beyond the slab edge (Figure1.2). This enables Voltex to be properly overlapped for subsequent slab section pours. Volclay Waterstop-RX should be installed in all slab construction joints where applicable (Figure 1.2).
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DARK GREY (WOVEN) GEOTEXTILE SIDE UP WITH VOLTEX OR VOLTEX DS Figure 1.3 Voltex installed directly over compacted earth/gravel substrate requires a minimum 150 mm thick reinforced slab.
Waterstop RX101 With Min. 75mm Concrete Cover. Fixed With Revofix Reinforced Concrete Slab Minimum 150mm Thick
V
30 0m m MI
X TE L O
m 0m 10
N.
VOLTEX
FORMWORK VOLTEX
RX101 WATERSTOP
VOLTEX
CONCRETE UNDERBLIND
CONCRETE UNDERBLINDING
.
100mm LAP
100mm LAP
RX101 WATERSTOP
100
LAP
CONTIGUOUS PILING.
RX 101 WATERSTOP
150mm LAP
VOLTEX
CONCRETE BLINDING
100 LAP
RC. SLAB
40X40mm FILLET OF BENTONITE PASTE (GRANULES & WATER) CONCRETE UNDERBLIND VOLTEX PILECAP
CONCRETE PILE.
100 LAP
RC. SLAB
CONCRETE UNDERBLIND
GROUND BEAM
VOLTEX
T OL
EX
T OL
EX
VOLTEX
Figure 1.15 Multiple pipe penetrations. Trowel Bentoseal around pipes and covering area between pipes
PIPES RX101 WATERSTOP AS A PUDDLEFLANGE.
VOLTEX
LAP
LAP
VOLTEX
VOLTEX
LIFT PIT
If Voltex is damaged during form removal along the lower edge of the slab, form a trough and fill it with Voltex Granules. Seat the vertical Voltex, on the edge of the slab, into the Voltex Granules. Volclay Waterstop-RX should be installed in the perimeter wall/slab intersection joint. The Voltex may be continued up to kicker level within the formwork. When the formwork is removed the Voltex will be mechanically attached (peel-adhered) to the face of the concrete. (Figure 1.18) Figure 1.18
VOLTEX TERMINATED AT KICKER LEVEL. KICKER FORMWORK SLAB EDGE FORMWORK
RC. SLAB
R.C SLAB
VOLTEX
VOLTEX DRESS THE VOLTEX UP THE PROPERTY LINE TO A POINT 250mm ABOVE THE KICKER JOINT TO FORM A 100mm LAP. RX101 WATERSTOP
100
250
GROUND ANCHOR
VOLTEX
CONCRETE BLINDING
10
Install succeeding Voltex course overlapping the previous course a minimum 100 mm, staggering the vertical overlap seams a minimum 300 mm (Figure 2.3). (Note: Lap seams so that the upper roll is over the lower rolls top edge.)
Figure 2.3
VOLTEX FIXED TO DIAPHRAGM WALL RC WALL WATERSTOP RX101 PUDDLE FLANGE SECURED WITH WIRE PIPE
Continue installing Voltex up to ground level. After the wall has been poured, terminate Voltex at ground level with a rigid termination bar fastened at 300 mm centres. A 300 mm wide strip of UV resistant flashing is recommended to be installed with the termination bar. Embed the top edge of Voltex and termination bar in a 50 mm wide by 12 mm thick bead of Bentoseal. (Figure 2.4)
PIPE
RETAINED EARTH
VOLTEX
BENTOSEAL SHEET PILE INTERLOCK
11
RX101 WATERSTOP
VO L
VO
LT
NOTE!
FIX VOLTEX TO FACE OF STEEL SHEET PILING OR PLYBOARD WITH THE DARK GREY SIDE FACING THE INSTALLER.
EX
Voltex can be applied over large, relatively shallow indentations. The surface should not contain voids or sharp protrusions in excess of 25 mm. Fill all voids with cementitious grout and remove protrusions prior to mounting Voltex (Figure 2.9).
Figure 2.8 Earth formed concrete retention wall with Concrete caisson supports (Plan view)
RETA IN ED EA R TH
C O N CR ETE C AISSO N
CONCRETE BLINDING
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Figure 2.9 Voltex Panel installation over an earth formed shotcrete retention wall.
SHOTCRETE RETAINING WALL IRREGULAR SURFACE GROUTED SMOOTH
VOLTEX
RETAINED EARTH
VOLTEX VOLTEX
100mm VOLTEX LAPS. DARK GREY (WOVEN) GEOTEXTILE FACING THE INSTALLER
C O NC R ETE C A ISSO N
R ETA IN ED EA R TH
VO LTEX G RO UT TH E R EC ESSES
N A T U R A L R O C K F O R M A T IO N
V O L T E X F IX E D TO SHOTCRETE
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RX 101 WATERSTOP
3.2 Installation
40X40 FILLET OF VOLCLAY PASTE
(GRANULES & WATER)
Before installing the first course of Voltex, place a 40x40mm fillet of Volclay Paste at the wall/footing inside corner (Figure 3.2). Beginning at the bottom corner of the wall, install Voltex horizontally oriented with 1.5 m on one wall and the remainder around the corner on the other wall surface (Figure 3.2). Cut the bottom edge of Voltex at the corner a minimum of 300 mm so that Voltex can be extended onto the footing. Fasten Voltex into position with washer headed fasteners. Then cut and install a Voltex section over the uncovered footing corner area. Apply Bentoseal at the Voltex section to Voltex overlaps (Figure 3.2). Install adjacent Voltex rolls of the bottom course horizontally oriented. Each roll should overlap the preceding roll a minimum 100 mm and should extend onto the footing a minimum 300 mm. At inside corners apply a continuous 40x40mm fillet of Bentoseal directly in the corner prior to installing Voltex (Figure 3.3). Stagger all vertical overlap joints a minimum of 150 mm (Figure 3.4). When hydrostatic conditions exist, the vertical wall Voltex should cover the entire footing and overlap the underslab waterproofing a minimum 300 mm (Figure 3.3).
150mm LAP
VOLTEX
CONCRETE BLINDING
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Figure 3.2 Start Voltex at the corner horizontally. Place Panel section at corner & Bentoseal
40X40mm FILLET OF VOLCLAY PASTE (GRANULES & WATER)
BENTOSEAL SEALANT
VO
VO
LT EX
LT
EX
BENTOSEAL SEALANT
VO
LT
EX
VO
LT
EX
Figure 3.3 Apply fillet of Bentoseal to internal corner beneath the Voltex.
VOLTEX
40X40mm FILLET OF VOLCLAY PASTE IN ALL INTERNAL CORNERS PRIOR TO FIXING VOLTEX
VOLTEX
Figure 3.4 Voltex installed on a backfilled wall, overlapped 100 mm with vertical joints staggered. INSTALL VOLTEX OR VOLTEX DS WITH DARK GREY (WOVEN) GEOTEXTILE SIDE AGAINST THE CONCRETE
VO
LT
EX VO
VO
LT
LT
EX
EX
VO
TYPICAL VOLTEX LAP 100mm RX101 WATERSTOP 40X40mm TRIANGULAR FILLET OF VOLCLAY PASTE (GRANULES&WATER) UNDER THE VOLTEX.
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PIPE WATERSTOP RX101 PUDDLE FLANGE SECURED WITH WIRE TROWEL BENTOSEAL AROUND MULTIPLE PENETRATIONS.
PIPE
The excavated area should be backfilled immediately after Voltex is installed and used as a platform in applying succeeding Voltex courses. However, several courses may be installed before backfilling. The backfill must be compacted to a minimum 85% Modified Proctor density.
3.4 Terminations
Voltex should be brought up to the ground level on vertical wall installations. Terminate Voltex at ground level with a rigid metal or plastic termination bar fastened at 300 mm centers. A 300 mm wide strip of UV resistant flashing is recommended to be installed with the termination bar at ground level (Figure 3.8). Embed the top edge of the Voltex and termination bar in 50 mm wide, 12 mm thick bead of Bentoseal. Alternate ground terminations are illustrated in Figures 3.9, 3.10, 3.11 and 3.12.
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35m m dia BEAD O F BENTOSEAL GROUND LEVEL 150 VO LTEX TERM INATIO N STRIP VO LTEX
GROUND LEVEL
150
VOLTEX RC WALL
RC W ALL
Figure 3.11 Termination above ground using a 300mm wide UV resistant membrane and a metal termination strip.
URETHANE CAULKING METAL TERMINATION STRIP GROUND LEVEL
GROUND LEVEL
RC W ALL
RC WALL
VOLTEX
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Staple Voltex edges together with a standard box stapler to keep the Voltex from moving during the backfill operation. Treat all penetrations with 40 mm thick fillet of Bentoseal. Bentoseal should extend onto Voltex and completely fill any area around the penetration (Figure 4.2). At tunnel surface edges, turn Voltex down onto the vertical wall surface covering the top edge of the vertical wall waterproofing a minimum of 300 mm (Figure 4.3). When backfilling, earth should be placed in front of the equipment so that the heavy wheels or tracks will travel on the fill and not directly on Voltex. Backfill should contain ground material 25 mm or less. A minimum 600 mm of backfill compacted to a minimum 85% Modified Proctor density is required over Voltex to provide containment ballast and protection from traffic (Figure 4.2). When a concrete slab less than 200 mm will be placed onto the tunnel roof, Volclay Swelltite is recommended. Consult CETCO for specific installation guidelines.
4.1 Installation
Prior to installing Voltex, distribute 3 mm of granular bentonite, Voltex Granules, onto the concrete roof deck. Install Voltex from the low point to the high point across the fall line to create a shingle type installation. Overlap Voltex edges a minimum 100 mm and stagger the transverse roll ends a minimum 300 mm (Figure 4.1).
VO
LT
RX101 WATERSTOP
300 lap
40X40mm FILLET OF BENTONITE PASTE UNDER VOLTEX CONCRETE TUNNEL RX101 WATERSTOP
VO
LT
EX
VO
LT
EX
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PIPE
MINIMUM SOIL COVER 600mm
BUILDING INTERIOR
WATERSTOP RX101
Figure 4.3 Tunnel roof installation detail. Apply a 3 mm layer of granular bentonite prior to Voltex
VOLTEX
WATERSTOP RX101
VO
LT
EX
FOR APPLICATIONS NOT COVERED IN THIS MANUAL, CONTACT CETCO FOR TECHNICAL ASSISTANCE AND INSTALLATION GUIDELINES.
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CONSTRUCTION WATERPROOFING GROUP Birch House Scotts Quays Birkenhead United Kingdom CH41 1FB Tel: +44 (0) 151 606 5900 Fax: +44 (0) 151 606 5932
LIMITED WARRANTY
The information and data contained herein are believed to be accurate and reliable. Specifications and other information contained herein supersede all previously printed material and are subject to change without notice. Manufacturers warranty of installed system is available. Contact seller for terms and sample documents including all limitations. All goods sold by seller are warranted to be free from defects in material and workmanship. The foregoing warranty is in lieu of and excludes all other warranties not expressly set forth herein, whether express or implied by operation of law or otherwise including but not limited to any implied warranties of merchantability or fitness. Seller shall not be liable for incidental or consequential losses, damages or expenses, directly or indirectly arising from the sale, handling or use of the goods, or from any other cause relating thereto, and sellers liability hereunder in any case is expressly limited to the replacement (in the form originally shipped) of goods not complying with this agreement or at sellers election, to the repayment of, or crediting buyer with, an amount equal to the purchase price of such goods, whether such claims are for breach of warranty or negligence. Any claim by buyer with reference to the goods sold hereunder for any cause shall be deemed waived by buyer unless submitted to seller in writing within thirty (30) days from the date buyer discovered or should of discovered, any claimed breach. Materials should be inspected and tested by purchaser prior to their use if product quality is subject to verification after shipment. Performance guarantees are normally supplied by the applicator. Note: Volclay Voltex is not an expansion joint material. Expansion joints shall be the responsibility of OTHERS.
U.S. Patents #4, 048, 373; #4, 139, 586; #4, 084, 362 Foreign Patents and Other Patents Pending AUGUST 2001 (Supersedes all previous versions)
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