Sprayed concrete –

à la carte
 UGC International is a world leader in the provision of reliable,
customer oriented product solutions focused on your needs
in the tunnelling and mining industries. We are part of BASF,
The Chemical Company, an established multinational company
with extensive support frameworks and resources which you
would expect from a leading worldwide construction chemicals
supplier.
UGC recognises that your success is founded on delivering
solutions that meet or exceed your customers’ valuable needs.
By integrating with you from project start-up and understanding
the issues that are important to you, we can contribute to your
success.
As many underground projects attract international contractor

Introduction – and design teams, our global presence permits seamless transfer
of technology and services to any of your projects, anywhere in
à la carte the world.

Sprayed concrete is widely used for ground support in tunnelling,

mining, hydropower construction and slope stabilization. As the world
leader, BASF UGC gives you not only cost effective products, but also
technical services that are tailored to your needs.

• A one-stop shop offering you both admixture technologies and

equipment for high quality sprayed concrete application
• Professional and competent technical services, provided by a team
of international and local tunnelling specialists, who are ready to be
«True
with you 24 hours a day, 7 days a week, helping you with product
partnership» training, technical advice, job site supervision, trouble shooting and
quality control
• Innovative solutions through Research & Development dedicated
to tunnelling needs
• Technical consulting at every project stage, from planning to com-
pletion, keeping you well informed about our technologies all the
time
• Laboratory resources at your disposal to carry out project specific
testing, helping you with product selection so that you get it right
the first time

«Save time • Our world-known reputation and reliability to give you the confi-
dence you require from a technology supplier
and cost»

«Customised
solutions»
 Pre/Post Injection
• RHEOCEM microcements
• MEYCO® MP acrylic and
polyurethane resins
• MEYCO® MP colloidal silica
Rock Bolting/Anchoring
• MEYCO® FIX Flowcable
Concrete mix design
• Superplasticizers
• DELVO®CRETE hydration control
additives
• MEYCO® TCC 735 Concrete Improver
• MEYCO® MS (Micro and Nano silica)

Sprayed concrete Equipment Spray-applied waterproofing Training & Service

accelerators • Full range of spraying membranes

Solutions – • Alkali-free liquid

accelerators: MEYCO® SA
mobiles for large or small
applications
• Tailor-made spraying
• MASTERSEAL® 345

à la carte
systems

«All from one»:

Admixtures – Equipment – Injection– Waterproofing – Fire protection

• MEYCO® SA range of alkali-free accelerators providing excellent

early and long term strength, and highly durable concrete. A family of
«Improve products is available to suit your site conditions
workplace • GLENIUM® and RHEOBUILD® range of high performing superplas-
safety» ticizers allowing you to achieve very low w/c in the concrete mix, and
high and extended workability
• DELVO®CRETE hydration control admixtures allowing you to pro-
long the workability of your concrete mix to suit site logistics
• MEYCO® TCC bond improving admixtures added at the batching plant
that internally cure the sprayed concrete immediately after spraying
• MEYCO® MS range of additives based on micro- and colloidal- silica
technologies that further enhance the strength and durability of your
sprayed concrete
«Computer &
• Steel and structural plastic fibres
laser controlled • State of the art concrete pumps and robotic spraying manipula-
robotic tors, for high quality and reliable concrete spraying
spraying» • MEYCO® Robojet Logica laser guided spraying robots, giving un-
precedented thickness control and quality assurance
• Injection solutions and spray-applied waterproofing memb-
ranes, giving you opportunities for monolithic, single shell lining
construction

«Single shell
sprayed concrete
lining»
 Batching + Transport
DELVO®CRETE Stabilizer
controls hydration
Puts fresh concrete to sleep

STOP
4h 72 h
DELVO®CRETE

Mix Design – DELVOCRETE®

à la carte
A wide range of admixtures and additives are available during the concrete batching in
order to ensure that demanding specifications are reached or exceeded.

Products Benefits
• Conventional Superplasticizers • RHEOBUILD® Lower w/c ratios, allowing
• High performance superplasticizers • GLENIUM® • Excellent early strength development
based on the latest MVA or poly- • High long term strength
carboxylate technologies • Improved durability
• Reduced accelerator consumption
• Reduced bleeding and segregation
• Pumping aid • MEYCO® TCC780 • Enhanced concrete pumping
• Pumping primer • MEYCO® Fix Lube • Especially useful for crushed or
poorly graded aggregates
• Hydration control • DELVO®CRETE stabilizers • Giving concrete a pot life of up to
«Mix design 72 hours
• Allowing total site flexibility
development • Bond improver / internal • MEYCO® TCC735 • Improved bonding of sprayed
support» curing aid concrete
• Curing the concrete internally
• Structural fibres • MEYCO® SP structural • Improved impact resistance
plastic fibres • Improved ductility
• Steel fibres • Replacing labour intensive mesh
reinforcement
• Other improvers • MEYCO® MS micro- and • For very high strength concrete
colloidal- silica • Improved setting and early strength
• Improved durability
• Improved watertightness

«Process
planning &
set-up support»
 Intermediate storage + Application
4–72 hours Wake up the sprayed concrete
with MEYCO® SA range of alkali-free
accelerators.

4h 72 h

Alkali-free accelerators –
à la carte
The MEYCO® SA series of alkali-free accelerators have been developed
in response to demand for high quality and durable sprayed concrete at
low health and environmental risk. They are an essential part of modern
sprayed concrete. Key benefits include:

• High performance with relatively low dosages

• Fast setting and constant early strength development allowing fast,
high build rates
• Ability to apply sprayed concrete in areas with some water ingress
• Successful sprayed concrete application in ground freezing projects
• Gives highly durable sprayed concrete
• Wide range of products to suit local cements, conditions
and site needs

MEYCO® SA series of alkali-free accelerators are probably the best known

and proven products in the market.

The benefits of MEYCO® SA alkali-free accelerators are maximized when

«Low health combined with our high performance GLENIUM® superplasticizers and
risk to DELVO®CRETE hydration control stabilizers. We recommend MEYCO®
Equipment incorporating integrated dosing system in order to ensure
operators»
accurate dosage control.

«Durable sprayed
concrete»
 Ground Loading

OPERATIONAL PERIOD CONSTRUCTION PERIOD

e.g. rail tunnel

Age of sprayed
100yr 50yr 25yr 10yr 2yr 1yr 90d 28d 14d 1d 12hr 6hr 1hr Time
concrete lining

Alkali-free Durable &

Environmentally safe
Cont‘d strength gain
Remaining safe
Fast setting & build
No «sleeping» period!
Remaining dry User safety
accelerators –
à la carte
Expectations of permanent sprayed concrete

100
Concrete properties are normally
determined by mix design parameters, a
Compressive strength (MPa)

b
such as w/c ratios, cement content,
c
fillers, among others. For sprayed 10

concrete, the choice of accelerators also

plays a vital role, both for early / long
term strength development, and for
1
durability properties.

0,1
0 min 6 min 15 min 30 min 1 hr 2 hr 4 hr 12 hr 24 hr
Time after spraying

60 60

a
50
Compressive strength (MPa)

40 40

30 30
c
CEM I R 42.5. w/c=0.42
20 20

a – MEYCO® SA product A
b – MEYCO® SA product B 10 10
c – Typical aluminate accelerator
0
1 7 28 90
Time in days

MEYCO® Oruga MEYCO® Roadrunner

 Equipment –
à la carte

• MEYCO® Logica technology: Spray robotic boom incorporating laser

guided automated application technology
• Fully equipped and modular spraying mobiles for the tunneling and
mining industries: MEYCO® Potenza, MEYCO® Cobra, MEYCO® Road-
runner
• Complete range of spraying manipulators, static or mobile: MEYCO®
Robojet, MEYCO® Oruga, MEYCO® Rama 4 or 6, MEYCO® Robojet
Minima
• Tailor made spray equipment for TBM, shaft plaftforms or special pro-
jects according to customer requirements
• MEYCO® Suprema – low pulsation double piston pump with integrated
dosing technology and data logging system
• MEYCO® Altera – Lower range double piston pump with integrated
dosing technology
• Dry spray equipment: the well proven rotor machines MEYCO® Piccola
and MEYCO® GM
• Accelerator dosing pumps and sprayed concrete dosing units
• Accessory and spare parts

MEYCO® Suprema MEYCO® Logica MEYCO® Potenza

 Temporary
sprayed concrete

Permanent cast
insitu concrete
lining

2 mm plastic
waterproofing
membrane sheet

Traditional technologies
Single shell Double
lining – shell lining
à la carte
Temporary support
design thickness

Permanent support
design thickness

Temporary sprayed concrete

(steel mesh reinforced)
Geotextile fleece
Plastic sheet membrane
(double welded joints)
Permanent in-situ cast concrete

Sprayed Concrete
Single Shell Lining Concept

• Primary rock support with sprayed concrete. High quality of the

sprayed concrete is achieved by
• Robotic wet-mix spraying for consistent high quality
• Use of alkali-free accelerators to ensure both short and
long term strength development
• Use of high performance superplasticisers to ensure
low permeability and high strength development
• Internal curring with MEYCO® TCC 735

The primary sprayed concrete forms part of the total lining design.
• A sprayable waterproofing membrane, such as MASTERSEAL® 345,
is applied onto the primary sprayed concrete to ensure complete
water tightness of the concrete lining.
• A secondary sprayed or cast concrete lining is applied, which acts
together with the primary sprayed concrete to complete the total
«Well proven lining.
• The spray applied membrane facilitates perfect bonding between
concept»
primary and secondary layer concrete, making the single shell
concept a reality.
 Primary
permanent sprayed
concrete lining

Secondary
permanent sprayed
or cast concrete lining

3 mm applied
waterproofing
membrane MASTERSEAL® 345
with FULL bonding to
sprayed concrete

New technologies
Single
shell lining
• Wet-mix process
• Alkali-free accelerators
• Low w/c using superplasticisers
• Microsilica technology
«Single shell
• Fibre reinforcement brings you
• Modern sprayed concrete equipment
Permanent support • MASTERSEAL® 345 spray applied membrane
cost and time
design thickness savings»
The saving

Primary permanent sprayed

concrete (fibre reinforced)

MASTERSEAL® 345

Secondary permanent sprayed

or in-situ cast concrete

Benefits of the single shell lining approach:

• Reduced excavation size

• Reduced overall lining thickness
• Less construction processes
«Use our global
• Reduced construction programme
experience!»
• Less cost (typically between 15 and 20%) compared
to double shell method
References –
à la carte
Europe & Middle East
• Gallerie in Valbadia (Bolzano), Italy
• St Martin La Porte, France
• Metro do Porto, Portugal
• Tunnel Los Mitte, Germany
• Trojane Tunnel, Slovenia
• North Cape tunnel; Lærdal tunnel, Norway
• Heathrow Express Terminal 5; Jubilee Line
Extension and Channel Tunnel Rail Link, UK
• Tramo Autopista Arguineguin / Tauro, Spain
• Kremsurprung Tunnel, Austria
• Ankara – Adana Highway, Turkey
• Loetschberg (Mitholz, Ferden, Steg / Raron; Gotthard
(Amsteg), Switzerland
• Meccah Tunnels, Saudi Arabia
North America
• Kidd Creek Mine, Canada
• Myra Falls Operations, Canada
• McArthur River Mine, Canada
• Weehawken Tunnel Project, US
• North Bergen Tunnel, US
• Exchange Place Station Rehabilitation, US
Asia Pacific
• Taiwan High Speed Rail Link, Taiwan
• Eagles Nest Tunnel – Route 8, Hong Kong
• Mandai Cavern, Singapore
• Seoul – Busan High Speed Rail Project, Korea
• Hai Van Pass Road Tunnel, Vietnam
• Longtan Hydro Electric Power Project, China
• Parramatta Rail Link, Sydney, Australia
• Penchala Road Tunnel, Kuala Lumpur, Malaysia
• Num Thuem 2 – Hydro Power Project, Laos
• Konan Tunnel; Rokando Tunnel; Imazato Daiichi
Tunnel, Japan
Latin America
• Santiago Metro, Line 4, Chile
• La Polvora Highway Tunnels, Chile
• El Cajon Hydroelectric Project, Mexico
• Interoceanica Highway Tunnel, Quito, Ecuador
• Sao Paulo Ring Road Tunnels, Brasil
«Together we do things better.»
 Headquarters: Machines/Equipment: Latin America:
UGC International MEYCO Equipment BASF Construction Chemicals
Division of BASF Division of BASF Latin America
Construction Chemicals (Switzerland) Ltd Construction Chemicals (Switzerland) Ltd 23700 Chagrin Boulevard
Vulkanstrasse 110 Hegmattenstrasse 24 Cleveland, OH 44122-5554
8048 Zurich, Switzerland 8404 Winterthur, Switzerland USA
Phone +41-58-958 22 11 Phone +41-58-958 27 00 Phone +1-216-839 75 00
Fax +41-58-958 32 46 Fax +41-58-958 37 07 Fax +1-216-839 88 26

Europe: North America: Asia Pacific:

BASF Construction Chemicals BASF Admixtures Inc. BASF Construction Chemicals
(Europe) AG Underground Construction Group Asia Pacific
Vulkanstrasse 110 23700 Chagrin Boulevard Room 2207, Shanghai Times Square
8048 Zurich, Switzerland Cleveland, OH 44122-5554 93 Huai Hai Zhong Road
Phone +41-58-958 22 11 USA Shanghai 200021, P.R. China
Fax +41-58-958 32 46 Phone +1-216-839 75 00 Phone +86-21-5133 2834
Fax +1-216-839 88 29 Fax +86-21-5306 9055

Further brochures on our à la carte solutions are available:

For your local BASF UGC representative, visit our website at www.ugc.basf.com.

Product liability: The information given here is true, represents our best knowledge and is based not only on laboratory
work but also on field experience. However, because of numerous factors affecting results, we offer this information without
guarantee and no patent liability is assumed.

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