Underground Construction Chemical

Ground Control Technology

Amstrong Tahija
Tunneling and Mining Technical Service
BASF’s segments as of January 1, 2015

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2
BASF in Indonesia

Key Facts

€492 million
sales in 2014

642
employees

4
production
sites Head Office and Plants Sales Office Field Representatives Location

Production sites
ISO 9001 &
ISO 14001
certified
Dispersions & Construction
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Construction Chemicals Division

BASF Construction Chemicals

Admixture Systems Construction Systems

Construction Chemicals 07 / 2006 – Klaus Kamhuber

Admixture Systems

Products
Market segments
▪ Superplasticizers
▪ Plasticizers
▪ Ready mix industry
▪ Retarders
▪ Pre cast industry
▪ Accelerators
▪ Manufactured concrete
▪ Freeze protection
products industry
▪ Air entrainers
▪ Construction companies
▪ Curing compounds
▪ Tunnel building industry
▪ Mold releases
▪ Mining industry
▪ Special underground
▪ Oil services industry
products ( UGC )
▪ Special oil field products

Construction Chemicals 07 / 2006 – Klaus Kamhuber

Construction Systems

Products Market segments

▪ Grouts
▪ Concrete repair systems ▪ Building merchants
▪ Tiling compounds ▪ Contractors and applicators
▪ Adhesives and injection ▪ Owner of buildings
▪ Flooring ▪ Construction Industry
▪ Sport surfaces ▪ Real Estate Companies
▪ Waterproofing (building management)
▪ Joint sealing ▪ Government Public Sector
▪ Corrosion protection
▪ Impregnation coating
▪ SOGIC Protective Coating

Construction Chemicals 07 / 2006 – Klaus Kamhuber

 BASF’s Involvement in Ground Control

1 Shotcrete
2
2 Injection – Pre or Post Injection
5
2 3 Backfill

1 4 Rock Bolting
4

5 Thin Sprayed Liners

6
6 Admixtures for Concrete
6 1 3

7
 1 Shotcrete

Shotcrete is concrete placed by shooting

The mix of sand, cement and or water is
conveyed by compressed air from the shotcrete
machine to the application gun/nozzle
An excellent technology for stabilization and
support of structures in a very quick time and
for concrete application without using
formwork
Shotcrete is also the interacting combination
of human, equipment and materials
Shotcrete can be used for many different
construction applications
Very flexible, economic and rapid construction
method, but it also requires a high degree of
mechanization and skillful specialist workers
are essential
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BASF – Shotcrete Admixtures (1)

Admixtures are chemicals, added in small amounts to change the

properties of the concrete in a plastic (fresh) state or after hardening
They are added during concrete batching at the plant or in the truck mixer
The main admixture types used for sprayed concrete applications include:
Superplasticizers
Hydration control admixtures
Internal curing and bond improving admixtures
Pumping aids

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BASF – Shotcrete Admixtures (2)
Superplasticizers
 Lower water/cement ratio improved strength and durability
 Increased workability  longer open time and improved pumping
 Typical dosages are 0.5 – 1.5 % bwc

BASF Superplasticiesers for Shotcrete

 MasterGlenium SKY 8770
 MasterGlenium 8316
 MasterEase 3073

Hydration Control Admixtures

 Delays hydration until an accelerator is added
 Improved freedom for concrete delivery/logistics
 Maintains concrete fresher at the point of use
 Supports acceleration process
 Typical dosages are 0.5 – 1.0 % bwc
 Note the difference between hydration control and retarder

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Stabilisers – Hydration Control
Admixtures (HCA)

Set accelerators -
Traditional
accelerate the
process sprayed concrete

No control!

Hydration control
admixtures - de- ... and reactivate and
New flexibility with
activate the accelerate the process
hydration .... hydration control
admixtures

Take back control!

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BASF – Shotcrete Admixtures (2)
Accelerator
 Improved working safety
 Less strength difference to base mix
 Less dust and rebound
 Improved sulphate resistance when using standard OPC
 Reduced environmental impact in hardened concrete

BASF Accelerator for Shotcrete

 MasterRoc SA 167 (Liquid)
 MasterRoc SA 160 (Liquid)
 MasterRoc SA 193 (Liquid)
 MasterRoc SA 192 (Liquid)
 MasterRoc SA 540 (Powder)

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BASF – Shotcrete Admixtures (3)

Pumping aids

Internal Curing and Bond Improver

Reduces the need for external curing (difficult underground)
Enhances interlayer bonding
Typical dosages are 1.0 % bwc

Shotcrete PrePack
 MasterRoc STS 20S - Prepack sprayed concrete material for
ease application in remote area

DD.MM.YYYY LORUM IPSUM DOLORES 13

Constituents – Concrete Improver

MasterRoc TCC 735

 “Internal” curing admixture may be added to the
mix at the batching plant along with other
admixtures

 These systems act immediately after spraying and

are active throughout the sprayed concrete lining

 No additional application steps as with water

sheets or external curing membrane methods,
causing a “film” on the sprayed concrete

 In addition to its curing properties, MasterRoc TCC

735 improves the bonding significantly

 Reduction of dust and rebound during spraying

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Constituents – Fibers
Improves
 Durability
 Ductility (Toughness)
 Impact Resistance
Resists flexural and shear
loading
Provides easy application
Offers safer working conditions
Provides easy encapsulation
while
reducing rebound and
sloughing
Reduces material usage
Reduces final costs
Excellent Resistance to drill &
blast operations

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Constituents – Fibers

Steel Fibers
To comply with EN 14889-1
Dosage range 35 – 65 kg per m3
Fiber lengths 19 – 35 mm
Diameter 0.5 mm – 2 mm
Tensile strength 900 – 1100 Mpa
Fiber per kg: 10000 – 15000
Drawn Wire, Enlarged End, Corrugated Type
Also available in Stainless Steel

Used in permanent structures, civil tunnelling projects, in seismic

active ground where sudden rock bursts occur and has a small
tolerance for crack widths.

Added to the mixer at the batching plant through a fibre dispenser

or directly into the truck mixer

Care must be taken during handling

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Constituents – Fibers

Structural Polypropylene Fibers

To comply with EN 14889-2
Dosage range 3 – 9 kg per m3
Fibers lengths 30 – 65 mm
Diameter 0.1 mm – 2.5 mm
Tensile strength 200 – 600 Mpa
Fibers per kg: 20000 – 70000
Melting Point: 160 – 190 degrees Celsius
Corrugated, Fibrillated, Embossed, Hydrophilic

Used in areas where large deformations are expected, larger

crack widths are accepted (mining) and a highly aggressive
environment

Added to the mixer at the batching plant through a fibers

dispenser or directly into the truck mixer
User friendly – no skin puncture

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 2 Injection – Pre or Post Injection

Pre Injection
 Pre-injection is like an insurance, to avoid problems in the future
 For poor ground stabilisation
 As part of a single shell shotcrete lining strategy
 Common used in

✓ Sub sea tunneling (or below lakes and rivers)

✓ Tunneling down slope ( water collecting at face )
✓ Tunneling with an access down slope All water must be pumped out
✓ Where high head GW in-rushes may occur
✓ To avoid surface settlements and damage

✓ For environmental protectionorkers are essential

18 1/9/2018
Injection – Pre Injection

DD.MM.YYYY LORUM IPSUM DOLORES 19

 2 Injection – Pre or Post Injection

BASF Pre Injection Product Range

▪ MasterRoc MP 650 - Fast setting micro-fine cement for

improvement of fractured rock and soil

▪ MasterRoc MP 320T - Hydrophilic colloidal silica grout for ground

improvement on sandy and silty strata

20 1/9/2018
Injection – Post Injection

Injection systems which give high strength within a few minutes

Typical use in situations where there is an urgent need for rapid
ground improvement

▪ Mines in faulted zones or areas with low rock strength

▪ Areas with high rock stress

▪ In tunneling when an instable situations (e.g. a developing collapse

with serious consequences)

▪ Stabilization of pillars and walls

▪ Highwall stabilization

21 1/9/2018
Injection – Post Injection

22 1/9/2018
Injection – Post Injection

23 1/9/2018
Injection – Post Injection

24 1/9/2018
Injection – Post Injection
BASF Post Injection Product Range

▪ MasterRoc MP 364 – 2 components fire-resistance

polyuria silicate resin with high bonding strength for ground
consolidation of fractured rock

▪ MasterRoc MP 367 – 2 components polyuria silicate resin

with high expansion foam for ground consolidation and
cavity filling

▪ MasterRoc MP 755 – 2 components polyuria silicate resin

with high expansion foam for ground consolidation and
cavity filling

▪ MasterRoc MP 355 1K - 1 component polyurethane resin

for small to medium rapid water-stopping
25 1/9/2018
 2 Injection – Pre or Post Injection
Pump Instalation

26 1/9/2018
 4 Rock Bolting - Anchoring
Rock bolts are often fully
encapsulated, resin or
cement anchored

Cable bolts or bolts can be

point resin anchored then
cement grouted

27 1/9/2018
Rock bolting and Cable bolting

Rock bolts and Cable bolts are used extensively in ground support
regimes in both metalliferous and coal mines.

This ground support or rock reinforcement is active support.

Huge range of ground support consumables are used

Main differences between coal and hard rock mines is due to speed of
mining and the geotechnical nature of the ground.

Also the degree of mechanization in the mines.

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Rock Bolting - Anchoring
BASF Product Range

Cementitious Product
➢ MasterRoc FLC 100 - Grout additive to
produce a pumpable, non shrink, non
segregating, impermeable grout providing
high strength & high bond to steel

➢ MasterRoc RBA 728 - Cement-based

cartridges for fully grouted or part grouted
rock anchors

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Rock Bolting - Anchoring
BASF Product Range

Cementitious Product
➢ MasterFlow 816 Grout – ready-to-use aggregate
free grout specially formulated for applications that
require a fluid shrinkage compensating grout where
clearances are shallow, grouting of tensioned cables
and rods stressed above 550 MPa

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Rock Bolting - Anchoring
BASF Product Range

Resin Product
➢ MasterRoc MP 364 – Highly reactive, two
component fire resistant polyurea silicate
injection resin for ground consolidation

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Rock Bolting - Anchoring
BASF Product Range

Resin Product
➢ MasterRoc RBA 380
– Highly reactive, fire
resistant thixotropic
polyurea silicate
injection resin for rock
bolting

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