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RESIN GROUTS
René P. Schmid
Rascor International Ltd - Systems Engineering for Waterproof Structures
Official Swiss Delegate to Working Group CEN TC 104 SC 8 TG4 Injection Technology
European Standards Committee Concrete Repairs
ABSTRACT: Times New Roman, 12 point font size, 150 words or less, summary / abstract of paper. This
document provides guidelines and instructions for the submission of full papers for the AITES-ITA
DOWNUNDER 2002, 28th ITA General Assembly and World Tunnel Congress. These instructions must be
strictly adhered to. If papers are received not in the format outlined, they may not be considered for inclusion
in the programme.
1 INTRODUCTION
Few of these, however, can be properly implemented
The main function of remedial work injections is in "building conditions". The product groups
normally to reinstate existing damaged structures for commonly used for grouting today may, on the basis
operational use. A major consideration is the of their market position, be reduced to the following:
minimum disruption to the use of the facility during
grouting operations. However the intelligent - EPOXY RESINS (EP)
combination of injectable channels and crack
inducers permits these techniques to be exploited to - POYURETHANES (PU/SPUR)
the full for preventive measures as well.
- ACRYLIC RESINS (AC/AMD)
Most products used today are freely available on the
market. Development is user-independent and their Again here there are wide differences due to their
application as wide, i.e. commercial, as possible. very specific application fields. These are the
Maximum potential applications promote sales and generally acknowledged market shares:
economic success. Such products may well suffice
in simple situations but can hardly cater for highly - epoxy resins approx. 3 %
technical demanding ones. A closed circle of
product development and manufacture, consultancy - polyurethane's and acrylic resins approx. 97 %
and application, i.e. a long-term association of all
those involved, creates broader and clearer A further breakdown of the second group is more
opportunities and clarifies the liability issue. problematic due to the absence of reliable statistics.
Products and plant can be tailored to suit local
conditions and particular requirements. This is a
prerequisite for optimum technical and economic 3 PRODUCT SELECTION ACCORDING TO
performance. FUNCTION AND PROPERTIES
Polyurethane resins have long been state-of-the-art Low viscosity two-pack acrylic resins are injected
products - so one might think. This is however only directly into the heart of the damaged area, i.e. into
true in cases where it is a matter of "cementing" the the load-bearing fabric, from where they spread out
past. Unlike other systems, PU-resins are through the finest pores and hairline cracks into the
manufactured and sold on the market for particular whole fabric and polymerise, producing an elastic
applications. This assists the "normal user" and cuts neutral end product. This allows a full seal with
down on errors but at the same time narrows down minimum material and short working times. The
opportunities. A basic distinction to be drawn is packers may be removed for reuse already minutes
whether operations are carried out under water after injection.
pressure - or - on a dry base since two completely
different procedures are necessary. All products are based on an aqueous two-pack
system of modified acrylic resins with a viscosity
When working under water pressure it is common to and surface tension adapted to water (with the
pre-grout with a "one-pack resin" that reacts quickly exception of formulations for expansion joints).
with water, i.e. modified isocyanates are premixed Depending on the condition of the building fabric,
with a catalyst. This produces a compound which the causes of existing damage and the required
remains workable for a long time and only reacts in solutions, different base compositions or variable
the presence of water (or humidity). The intense formulations have been implemented to achieve the
reaction induced by water produces carbon dioxide required performance. The special characteristics of
(CO2) and thus a variably strong foaming effect. the material often bring solutions to seemingly
The quick reaction makes such systems suitable for insuperable problems. For example grouting against
holding back water. The fine pore structure tends to direct water counter-pressure (flowing water) is
lose volume (lost gas) with time and at high possible. The grouting pressure need only be greater
pressures there is the risk of cell walls caving in. than that of the ingressing water. The residual water
This is not then a permanent solution. in the grouting zone is integrated into the
polymerisation process. Two-stage grouting as with
As a result, secondary grouting operation need to be polyurethane is not necessary.
carried out using slow reacting two-pack resins
which themselves cannot be used under water The elastic end product, resulting from
pressure. The one-pack preseal allows the second polymerisation under appropriate pressure, grips the
injection to react unhindered, producing a fabric by virtue of its pre-tension to produce a
permanently waterproof mass. Of course the two- perfect seal. This means that actual bonding with the
pack injection can be used alone as a preventive fabric is unnecessary as long as there is no
measure with dry or only slightly damp cracks. expansion of the joint or crack width greater than
15%. This explains why cracks, joints and porous
These two-pack polyurethane's usually consist of fabric require no cleaning prior to grouting, i.e. a
polyol and isocyanates. Foaming is minimal and a perfect seal is possible even on oily, calcined or
closed-cell structure of individual bubbles is formed. dusty contact surfaces.
The relatively high elasticity allows their use in
cracks with limited movement. Here the crack width The end product is chemically neutral, totally
is very important, i.e. the wider the crack the larger insoluble and resists rotting and decomposition. Use
the expandibility. With cracks below 0.5 mm one in potable water containers is unproblematic. The
can hardly speak of expandibility. properties and elasticity of the polymer remain
unchanged within the temperature range -25 to +90
C, and there is no significant change in volume
within this range, i.e. no hydraulic pressure through material loss which allow pressure or vacuum build-
frost action. up within the crack. Rapid-hardening cement
mortars, two-pack reactive resins or reactive resin
Striking differences compared to other product mortars and pastes are used. Cracks are rarely closed
groups include: with mastic compounds due to their low pressure
resistance. Special systems provide thermal shock
- mixing ratio A:B = 1:1 (weight or volume) treatment for the discharged resin - without
- aqueous solution with surface tension adapted to detriment to the building fabric - thus considerably
water (self-mixing effect) reducing preparation times.
The above presentation has outlined areas of great Table 6 Plasticity Temperatures from Temperature
potential. What has been said is more or less Deformation Curves
applicable to all types of structure. It should,
1)
however, be clearly stated that such results can only Individual Values x1, x2, x3, Average Value x
be produced where a prior in-depth failure analysis
is undertaken, where the appropriate formulations Table 7 Properties of Polyurethane Resins
and equipment are used and where the operative is
well trained and has the necessary experience. If Table 8 Comparison of Properties of 3 Acrylate
carefully planned and executed by established and Formulations Prior to & After Polymerisation
experienced contractors, the good grouting
technology available today bears no exceptional Table 9 Shrinkage and Expansion Characteristics
risks. It must be emphasised however that, especially of 2 different Acrylate Formulations
for structural bonding applications, the selection of
the wrong material or faulty execution can rule out
the possibility of further repairs, which might mean
the end of the structure. Volume Shrinkage & Expansion of Acrylates I and
III vs Time in Days
Grouting work is not an alternative employment to
reduce over-capacities that exist elsewhere
9 REFERENCES
8 APPENDICES
1. Cementbulletin 4/82 (Schweiz. Zementverein)
Table:
2. Verpressharz-Versuchsreihe des jbac – Institut
1. Comparison of Area of Application and Product für Bauforschung der Techn. Hochschule,
Suitablity (above) Aachen
2. Product Properties of Various Resin
Formulations (above) 3 René P. Schmid. Elastische
3. Properties of 9 different Epoxy Resin Kunstharzinjektionen als Präventiv-oder
Formulations Sanierungsmassnahme B+B 2/84)
4. Bonding and Tearing Strength relative to Degree
of Hardening of Various Epoxy Products 4 Cornely, 1988 a
5. Shear Strength
6. Plasticity Temperatures from Temperature 5 Martin Smith. Waterproofing Structures:
Deformation Curves Lessons from the Past, Systems for the Future.
7. Properties of Polyurethane Resins
8. Comparison of Properties of 3 Acrylate
Formulations Prior to & After Polymerisation
9. Shrinkage and Expansion Characteristics of 2
different Acrylate Formulations