Method Statement Installation Tunnel membranes

Edition 13/12/2004
Author: H.J. Stich
Waterproofing works

Method Statement waterproofing works

Method Statement waterproofing works

Installation of Sikaplan® - Tunnel waterproofing membranes
Construction

General
This method statement describes the installation(*) of Sikaplan® Tunnel
waterproofing membranes (*installation = supply, unrolling, positioning, fixing and
overlap-welding of pre-manufactured waterproofing membranes)
Reinforced concrete structures, faced to ground are as such not watertight.
Project Waterproofing measurements are therefore, depending to the purpose of structure,
information required in order to prevent leaks into structure and to protect the structure against.
harmful influence of aggressive groundwater.
The high flexible and single layered waterproofing membrane protect the area of a
structure, exposed to ground, against seepage- and hydrostatic groundwater. In
case of a leak in waterproofing membrane and due to loosely laid and single layer
system, infiltrating water might spread uncontrolled between installed membrane
and structure. This can be get under control with compartment system in order to
minimise the spread of infiltrated water to a defined area. Control- and injection
pipes in structures, located in each compartment area assures possibility of control
and repair whenever required.
Criterions The main criterions for planning and execution of flexible waterproofing against
groundwater at underground structures are:

-Kind and purpose of structure

-Waterproofing of structures in open cut, mining or shafting
-Circumference of waterproofing (level of waterproofing termination)
-Kind and design of retention walls
-Pile foundations
-Lowering of groundwater level during construction (method)
-Conditions of waterproofing substrate
-Measurement of structure (length, width, depth)
-Groundwater level (max., min., average, immersion depth of structure)
-Expansion joints
-Phases and jointing of structure (construction schedule)

In order to avoid any kind of damages of the installed waterproofing membrane and
to assure its proper function as waterproofing, following requirements to the
substrate shall be fulfilled:
-The construction shall be designed to minimise movement of the structure, due to
temperature, settlement and contraction
-Reinforcement bars in concrete structures shall be min. 50mm below surface
-All steel elements shall be stainless, or anticorrosive materials (i.e. cast iron, V2A,
V4A steel quality, aluminium)
-The surface of substrate shall be smooth to avoid punctures of membrane under
influence of hydrostatic pressure

1 1/7
Preparation works
2
Materials stockyard A secured area of approx. 300 – 500m (i.e. storage hall, or open ground) to store
rolls of membranes, geotextiles, waterbars and all its required auxiliary products
with accessibility to lifting and carrying equipment to secure logistic from stockyard
to tunnel portals and to installation site in the tunnels. Membranes shall be stored
weathering protected. The quantities of waterproofing membranes and geotextiles
2
in stockyards shall at no time be less than 5000m each.
Installation equipment Supply and install movable scaffoldings for membrane installations, i.e.:
- prefab. membrane installation machine with movable working platform,
designed for actual tunnel-radius
- prefab. membrane installation platform (mobile and manual driven) for linings in
narrow cross passages
- mobile hydro-pneumatic movable working platform (alternative to installation
machine, available from local)
- illumination equipment, to be mounted at installation scaffolding
- power supply with 380V/220V to installation area to drive welding equipments
- equipments, to lift membrane and geotextile rolls on working platforms, i.e. with
light hydraulic cranes
The installation equipment for mining tunnel whatsoever, shall be constructed in
“portal form” founded on rail tracks on the horizontal surface of bottom, with clear
space in center, in order to allow underpassing of construction vehicle traffic.
Alternatively, the installation equipment shall be constructed in such condition, that
it can be displaced after completion of each waterproofing section, in order to clear
the way for construction traffic afterwards.
Substrate conditions
General Wet substrates to be lined with loose laid and spotwise fixed sheet membranes are
acceptable for installation. Running and ponding waters must be removed and/or
drained, prior to sheet membrane installation by main contractor until completion of
waterproofing works.
Substrates Waterproofing sections, with membrane installation on shotcrete (initial lining):
The surface of shotcrete shall be smooth and even. The shotcrete aggregate shall
have dia. 0mm – max. 4mm. Min. radius of any unevenness shall be not less than
20cm. Loose and protruding stones must be removed. The shotcrete shall be cured
at least for min. 24 hours. Steel elements, such as reinforcement bars, steel girders
and heats of rock bolts as far as not used to hold inner lining structures shall be
covered min. 5cm.
Running water ingress can be plugged with plugging mortars (i.e. Sika® 4A
admixture) mixed with brand new Portland cement, prior to initial lining.
Waters of heavy ingress can be collected into PVC half-pipe (i.e. Aliva® Half Pipe),
to be mounted by nailing, and led into permament drainage system. The mounted
half pipe shall be covered at least with min. 5cm thick shotcrete layer, prior to initial
lining.

Material
requirements
Geotextiles The geotextile to be installed on prepared substrate shall have the function of a
cushion layer to protect the membrane against puncturing, as well as drainage layer
to lead seepage waters to bottom area.
The geotextile shall be material (compatible to PVC membranes and cementitious
substrates), such as Polypropylene non woven fabric with needled, or thermal
cured endless fibre (chemical cured fibre are not allowed).
Physical properties (i.e. type Stratum / manufacturer: Vigano Pavitex, Italy):
- Unit weight: >500g/m² as per NF.G 38013
- Thickness: >4.00mm as per NF.G 38012
- Tensile strength: >500N/50mm as per DIN 53857/2
- Elongation: >80% as per DIN 53857/2
- Perforation: CBR >1600N as per DIN 54307
-3
- Water permeability: 4x10 m/sec as per NF.G 38016

2 Method statements waterproofing works 2/7

Pre-manufactured Sikaplan® Tunnel waterproofing membranes are laminated membrane on base of
waterproofing membrane plastified and unreinforced Polyvinilchloride, resp. flexible Polyolefines. The
laminated top layer of the membrane has yellow, resp. light grey colour with the
function of a signal layer as indicator for easy detection of mechanical damages
when exposed during construction period, and the bottom layer has dark grey
colour.
Physical properties as per DIN 16938 (Germany):
- Membrane thickness: 1.50 - 3.00mm (+0.2/-01mm) as per DIN 53370
- Tensile strength: >15 N/mm² as per DIN 53455
- Elongation: >300% as per DIN 53455
- Perforation resistance: tight at >750mm/500g, as per DIN16726
- Folding in cold: no cracks at -20°C as per DIN 16726
- Slit pressure resistance: watertight at 4bar/72 hours as per DIN16726
- Seam strength: crack must occur next to seam as per DIN16726
- Thermal ageing: <±20% deviations in tensile strength and elongation,
DIN16726
- Behaviour in fire: resistance class B2 as per DIN 4102
or class 5 as per SIA V 280

Waterbars The waterproofing membrane shall be terminated and where required, comparted
with waterbars type Sika® Waterbar type AR. The waterbar consist of plastified
Polyvinilchloride (PVC) and is compatible to the installed PVC waterproofing
membrane.
The waterbars must be heat welded on installed waterproofing membrane

Requirements:
- size: thickness >3.50mm
- width: > 250mm
- number of rips: >4
- rip height: >25mm

The waterbar comply with the specifications:

- No. CRD-C 572-74 of US Corps of Engineers
- B.S. 2571 and B.S. 2782.
It shall be tested according to A.S.T.M. Specification D-412/D-624/D746.

Fixing elements The elements for spotwise fixing of geotextile and waterproofing membrane are
roundels with dia. 100mm in plastified Polyvinilchloride (i.e. Sika® Disc), in order to
allow heat welding at waterproofing membrane. It is compatible to the common
used pistol-nailing technique (i.e Hilti DX 36 system).

Joint profiles In order to achieve watertightness of joints of slab concrete on bottom (joints
between slab and walls), as well as joints between prefab elements and in-situ
concrete of inner lining, the application of prefab joint profiles, similar to Sika®
Swell Profiles, type P (20mm x 5mm, EPDM profile which swells its volume, once in
contact with water) is recommended.

Re-injectable tubes For the possibility of later waterproofings in case of leaks, re-injectable tubes, i.e.
Sika® Injectoflex System, shall be installed into the joints between concrete slab
units and in-situ concrete inner lining at the bottom, prior to concreting works.
The system contain:
-injection tubes integrated in swellable profile
-tube connecting elements
-corner elements
-injection nipples
-elements for hose - fixing
Cleaner for PVC A solvent-free cleaner (i.e. Sika® -Trocal Cleaner 2000) must be used as cleaner
membranes and PVC for PVC membrane surface area to be welded in case of oil or fat. Dust and dirt
waterbars shall be wiped - off with clear water and rag.

3 Method statements waterproofing works 3/7

Installation
procedure
Installation of Supply rolls of geotextile (roll width 2.00m – 4.00m, depending to used product) and
geotextiles suspend roll at unrolling hook on installation platform. Reset working platform
parallel to tunnel axis at one lateral edge of waterproofing area. Unrolling of
geotextile (loose laid) by moving of working platform until level of horizontal tunnel
axis. Fix geotextile with fixing elements (PVC-roundels and nailing gun) at this level.
Continue unrolling along excavation line (resp. shotcrete surface) until other lateral
edge of waterproofing area and fix according to separate fixing plan. Unrolling
direction almost rectangular to tunnel axis. Once first geotextile-section completed,
move working platform to next section and repeat procedure, considering 100mm
overlap to already installed geotextile. Overlaps of geotextiles shall be sticked by
hand and warm-up under aid of hand held heat welder (hot air welder type Leister
Triac, heating temperature set at approx. 100°C).
Ambient temperature range for works: 0°C – 35°C
2
Theoretical consumption of fixing elements (roundel and nail): 1.3 pcs./m
Installation capacity (experienced 3-men team): approx. 80m2 / hour
Installation of Supply rolls of waterproofing membrane (roll width 2.20m) and suspend roll at
waterproofing unrolling hook on installation platform. Reset working platform parallel to tunnel axis
membrane at one lateral edge of waterproofing area. Unrolling of waterproofing membrane
(loose laid) by moving of working platform until level of horizontal tunnel axis. Start
fixing waterproofing membrane by heat welding on all fixed PVC-roundels with the
aid of hand held welding gun (type Leister Triac: welding temperature set at approx.
300-350°C) and press membrane firmly by hand on roundel. Unrolling direction
almost rectangular to tunnel axis. Once first membrane-section completed, move
working platform to next section and repeat procedure, considering 80mm overlap
to already installed membrane. Overlaps of membrane shall be heat welded with
automatic welding machine (type Leister Twinny T, or Leister type X – 84: self
propelled double seam welding machine) continuously from one membrane end
until the other. The welded seams shall be tested for watertightness with
compressed air under aid of seam testing kit. Each welded seam shall be
numbered and identified in its position and result of seam test shall be recorded in
sheet paper to be signed by waterproofing contractor and client.
Ambient temperature range for works: 0°C – 35°C
Installation capacity (experienced 3-men team: membrane unrolling, fixing and heat
2
welding): approx. 60m / hour
Heat welding procedure The membrane surfaces to be welded shall be clean, dry and free of fat or oil. Fat
for membrane overlaps or oil shall be cleaned with dry and white cotton rags and Sika®-Trocal Cleaner
2000 (solvent-free cleaner for PVC membranes).
Prior to any welding works, the welding parameters (speed, temperature and
pressure of rollers) shall be adjusted at the automatic welding machine and tested
at separate membrane specimen.
Reset working platform parallel to tunnel axis at one lateral edge of installed
waterproofing membrane. Clamp membrane overlaps at membrane end into
welding machine, insert welding nozzle into overlap and start machine self-traction.
Lead the machine at hand held along overlap, and follow movement with working
platform at the same speed than welding machine. This welding procedure shall be
performed without interruption until other end waterproofing membrane. All overlaps
within the tunnel profiles (excl. details) shall be performed with double seam
welding (two seams with air testing channel).
Details (i.e. membrane intersection to waterproofing of cross passage, jet fan
niches, station boxes, penetrations of anchors, etc.) shall be performed by hand
held welding machine and pressure roller (i.e. type Leister Triac) as single seam
welding. Membrane overlaps shall be min. 50mm
Approval of welded All welded membrane seams shall be tested on its watertightness.
seams Double seams (performed by Leister Twinny T, or Leister X-84):
All double seams shall be tested with compressed air testing kit
Total overlap: 80mm
Inner seam width 15mm / air channel width 10mm/ outer seam width 15mm
Close air channel at both membrane ends with clamp
Insert testing needle, connected with reverse flow valve and manometer at one
membrane overlap end. Connect testing needle with hose of manual, or electric
compressed air pump. Inflate air channel until pressure of 2.0 bar is achieved.
Close reverse flow valve. Disconnect hose from testing needle. Check air pressure

4 Method statements waterproofing works 4/7

 20 minutes after inflation procedure. The welded seam can be regarded as tight, if
the pressure decrease is less than 20%. Release clamp from membrane ends.
Heat weld membrane patch over membrane penetration, caused by insertion of
testing needle with hand held welding machine. Sign approved and tight seam with
marking pen. Record the test in paper sheet form. Repeat this procedure at all
double seams.
If test of double seam welding fails, inflate double seam again and search for leaks.
Once detected, repair with membrane patch to be heat welded with hand held
welding machine over defective area.
Single seams (performed by Leister Triac and hand held pressure roller):
All single seams shall be tested visually with the aid of screw driver
Total overlap: min. 50mm
Width of welded seam: min. 30mm, max. 40mm
Glide screw driver (approx. size 5) firmly along seam edge to search for capillaries
and voids. A continuous welding rope along membrane edge shall be visible.
Interrupted rope can be the sign of voids. Once a void detected, repair with
membrane patch to be heat welded with hand held welding machine over defective
area.
Approval of single seams (i.e. patches and membrane repairs) with vacuum bell on
demand:
Connect vacuum bell with hose to vacuum pump. Apply soap solution at seam edge
to be approved. Press vacuum bell firmly over control-area. Open reverse flow
valve and start vacuum pump until max. vacuum of – 0.5 bar. Control seams
through vacuum bell for bubbling soap solution. Seam can be regarded as tight, if
applied soap solution do not show bubbling.
Welding of waterbars on Preparation:
membrane terminations
Supply and unroll waterbar (i.e. Sika® Waterbar type AR 24) on surface of prefab.
concrete units. Waterbars shall be butt jointed under air of heat welding equipments
(either Leister heat welder with special flat nozzle, or el. heating sword). The ends
of waterbars shall be clamped into fixing tool for welding procedure. Protruding
welding rope at the flat side of waterbar must be cut – off with knife.
Lift the ends of installed and welded membrane edge on concrete element for
welding procedure. The membrane surface shall be clean, dry and free of fat or oil.
Lay prepared waterbar on membrane, approx. 10mm apart from membrane edge.

Welding:
A welding machine, specially designed for welding of waterbars on membrane shall
be used (i.e. Leister type Triac Drive, semi-automatic, single seam welding machine
with 12 mm nozzle)
Prior to any welding works, the welding parameters (speed, temperature and
levelling of rollers) shall be adjusted at the semi-automatic welding machine and
tested at separate membrane / waterbar specimen.
Set machine at end lap of waterbar, insert nozzle between waterbar and
membrane, press machine firmly and in upright position and start machine self
traction. Lead the machine by firmly pressing along waterbar edge until end of
welding. Repeat this procedure at the opposite edge of waterbar.
Once welding is completed, replace membrane edge with on-welded waterbar back
into definite position.

Welding machines:
Requested installation
Automatic (= self driver with adjustable speed and temperature, overlaps clamped):
tools and machineries
- Leister Twinny T, el. self propelled double seam welding machine with double
traction
- (Alternative to Twinny T) Leister X -84, el. self propelled double seam welding
machine with single traction
Semi-automatic (= self driver with adjustable speed and temperature):
- Leister Triac Drive, el. self propelled single seam welding machine with single
traction for welding of waterbars on waterproofing membrane
Manual welding (= hand-held welder with adjustable temperature and hand-held
pressure roller):
- Leister Triac, el., driven by hand pressure and with hand held pressure roller

5 Method statements waterproofing works 5/7

 - Special nozzle, adaptive to Leister Triac, for butt jointing (welding) of waterbars
Fixing Clamp, to fix butt joints of waterbars, compatible to type AR 24 (available
from Sika Plastiment, Austria)

Testing kit for double seam weldings of (available from Leister):

- testing needle with reverse flow valve and manometer
- manual compressed air pump (alternatively el. portable pump)

Testing kit for seam control of patches (available from Herz GmbH, Germany):
- translucent vacuum bell with rubber lips, reverse flow valve and manometer
- el. vacuum pump, portable

Inspection and
acceptance of The membrane shall be cleaned and inspected prior to concrete inner lining.
Representatives from waterproofing contractor and from client shall inspect the
completed
completed works. The inspection shall be recorded in written report to be signed by
waterproofing works both parties.

Installation works shall be performed by Sika STM - approved membrane installers

Installation Limits only
The specified membranes and waterbars are not resistant in permanent contact
with other building materials, like bitumen, and other kind plastics than PVC;
2
membrane requests almost separation layers in form of geotextiles > 500g/m to be
underlaid.

The membrane is not UV-stabilised and shall not be installed at structures,

permanent exposed to weathering, neither shall it be stored exposed to direct sun
All waterproofing products shall be subjected to standardized quality control system
Quality control as follows:
- quality control of materials, delivered to stockyard on site, such as conformity
of quantity and quality of material, incl. control of stock
- professional logistic from stockyard to installation site (careful handling)
- inspection of substrates, prior to waterproofing works
- inspection of professionality of waterproofing contractor on site
- throughout control of watertightness of welded seams
- final inspection of completed works, prior to further concreting works
Standardized quality control system is available of separate sheet forms

Local Restrictions

6 Method statements waterproofing works 6/7

 The waterproofing works shall comply with local:
Health and Safety - Dangerous Goods Regulations
Information
- Construction Safety Regulations
- Factories, Shop and Industries Regulation
Protective Measures Not required
Local regulations must be observed.
Fresh air ventilation is recommended, when working in closed rooms
Important Notes Recommendation: material is recyclable. Disposal according to local restrictions
Detailed health and safety information as well as detailed precautionary measures
e.g. physical, toxicological and ecological data can be obtained from the safety data
sheet of products.
The information, and, in particular, the recommendations relating to the application
Legal Notes and end-use of Sika products, are given in good faith based on Sika's current
knowledge and experience of the products when properly stored, handled and
applied under normal conditions. In practice, the differences in materials, substrates
Construction

and actual site conditions are such that no warranty in respect of merchantability or
of fitness for a particular purpose, nor any liability arising out of any legal
relationship whatsoever, can be inferred either from this information, or from any
written recommendations, or from any other advice offered. The proprietary rights of
third parties must be observed. All orders are accepted subject to our current terms
of sale and delivery. Users should always refer to the most recent issue of the
Product Data Sheet for the product concerned, copies of which will be supplied on
request.

Sika Services AG
Tüffenwies 16 Phone +41 1 436 40 40
CH-8048 Zurich Telefax +41 1 436 46 86
Switzerland www.sika-construction.com

7 Method statements waterproofing works 7/7