TUNNEL AND UNDERGROUND

WATERPROOFING WITH
MAPEPLAN SYSTEM

UNDERGROUND
www.utt-mapei.com
TECHNOLOGY
BY MAPEI _3
KURORTNYY PROSPEKT, TUNNEL N 5
Sochi - Russia

HONG KONG MTRC822

 PEDEMONTATNA VENETA
Brogliano - Vicenza (Italy)
INDEX

page 2 1. APPLICATION AREAS

page 3 2. CONSTRUCTION TYPOLOGIES

page 4 3. WATERPROOFING SYSTEM

page 4 3.1. PRE-INJECTION SYSTEM IN PRESENCE

OF WATER

page 5 3.2. SYNTHETIC WATERPROOFING MEMBRANE

page 5 3.2.1. RAW MATERIALS
page 5 3.2.2. MAPEPLAN PVC-P AND FPO MEMBRANES:
MAIN CHARACTERISTICS
page 7 3.2.3. STANDARD AND TESTS
page 10 3.2.4. SYNTHETIC WATERPROOFING MEMBRANES
SYSTEMS
page 18 3.2.5. TECHNICAL DRAWINGS
LILLIAN TOWER FOUNDATION page 23 3.2.6. MAPEPLAN ACCESSORIES
Dubai - UAE
page 29 3.2.7. INSTALLATION TOOLS
page 31 3.2.8. RISK MITIGATION: CHECK LIST FOR
WATERPROOFING
(INSPECTION, WELDING TESTS)

page 37 3.3. POST-INJECTION SYSTEM

page 39 3.4. SPRYABLE WATERPROOFING MEMBRANE AND

SYNTHETIC WATERPROOFING MEMBRANE
page 39 3.4.4. SPRYABLE WATERPROOFING MEMBRANE
AND PVC

UNDERGROUND
TECHNOLOGY
BY MAPEI _1
1. APPLICATION AREAS

APPLICATION FIELDS DESTINATION USE

DRILL AND BLAST TUNNELS ROAD TUNNELS WATER TUNNELS

CUT AND COVER TUNNELS METRO TUNNELS FOUNDATIONS
UNDERGROUND STRUCTURES RAIL TUNNELS METRO STATIONS

Foundation (Pearl Maison - Doha - Qatar) Metro Station (Riyad Metro Line 3)

Road Tunnel (Turecky Tunnel - Slovakia) Metro Tunnel (Farringdon station - Crossrail project -
London (UK)

UNDERGROUND
TECHNOLOGY
_2 BY MAPEI
 2. CONSTRUCTION TYPOLOGIES
DRAINED TUNNELS (UMBRELLA SYSTEM)
Permanent drainage concept
Standard waterproofing system

TUNNEL AUTOPISTA LLANO,

Bogot - Villavicencio, Colombia

UNDRAINED TUNNEL (FULL ROUND SYSTEM)

Top level of waterproofing system
Environmentally friendly
No influence of water table after construction

FARRINGDON STATION, Crossrail project

London (UK)

UNDERGROUND
TECHNOLOGY
BY MAPEI _3
3. WATERPROOFING SYSTEM
3.1. PRE-INJECTION SYSTEM IN PRESENCE
OF WATER

In presence of high water table pre-injection operations are required to prevent

the water inflow and allow the installation of waterproofing membrane.
The choice of products is carried out according to the following parameters:
- Soil permeability
- Water content
- Post-injected soil mechanical characteristics required
A fully range of injection products has been developed by Mapeis laboratories
in order to match needs and requirements of different jobsites*.

*find all products range and field of application in specific injection synoptic
table.

PRE-INJECTION CONCEPT

BOREHOLE DRILLING, POSITIONING OF

SLEEVED PIPE, REALIZATION OF SHEATH INJECTION
Soil Not treated soil

Valve Open injection

valve

Packer
Sheath
(cement+bentonite)

Sheath
Sleeved pipe
(cement+bentonite)

Sleeved pipe

Valve Close valve

Injected soil

Turin subway: bottom slab waterproofing

UNDERGROUND
TECHNOLOGY
_4 BY MAPEI
 3.2. SYNTHETIC WATERPROOFING MEMBRANE

3.2.1. RAW MATERIALS

PVC-P (polyvinyl chloride)

FPO (flexible polyolefin)

According to the worldwide experiences (> 50 years) the nowdays most used
polymer is the PVC-P with a life expectancy higher than 100 years.
Mapei has developed in its own laboratories high performance PVC-P and
high flexible FPO membranes.

3.2.2. MAPEPLAN PVC-P AND FPO MEMBRANES:

MAIN CHARACTERISTICS

PVC-P FPO

Signal layer or innovative warning layer Signal layer

High workability and good welding characteristics High workability and good welding characteristics

High resistance to root action and microbiological attak High resistance to root action and microbiological attak

High flexibility at low temperature High flexibility at low temperature

High resistance to stray currents High resistance to stray currents

High resistance to ageing High resistance to ageing

Self-extinguish Self-extinguish

Suitable contact with both alkaline and acidic water Suitable contact with both alkaline and acidic water

Radon - proof Radon - proof

Excellent dimensional stability Excellent dimensional stability

High mechanical resistance High mechanical resistance

It can be applied on damp substrates It can be applied on damp substrates

Formulation without dangerous or harmful substances Formulation without dangerous or harmful substances
for human health and the environment for human health and the environment

High resistance to permanent pressure Excellent resistance to ageing

Explosion resistance Formulation without plasticizer

UNDERGROUND
TECHNOLOGY
BY MAPEI _5
INNOVATIVE WARNING LAYER CONCEPT *
The thinner warning layer concept allows for the easier detection of any
damage, even when minimal. Such damage may occur during the installation
and/or during all of the subsequent working phases. Thus it helps safeguard
the integrity of the whole waterproofing system.

INTRODUCTION AND PURPOSE OF THE STUDY

The purpose of the study was to compare the resistance to abrasion
(according to UNI EN ISO 5470-1) of two PVC-P waterproofing membranes.
Namely, MAPEPLAN TU 20 (2.0 mm thickness with an orange signal layer
of 0.4 mm nominal thickness) and MAPEPLAN TU WL 20 (2.0 mm thickness
with warning layer of <0.20 mm nominal thickness). The following equipment
was used to highlight the different physical and mechanical properties and
performances.

1. ABRASION TEST, LABORATORY EQUIPMENT

The Taber abrasion equipment used for the test consists of:
Support,
Sample holder,
Circular plate,
A pair of swinging arms onto which abrasive wheels can be fixed, Abrasion test equipment
Motor for rotating the sample holder in the plane of its surface,
Rev counter,
Device for automatic stopping after a set number of laps (600 revolutions)
Suction device for removal of the waste.

2. ANALYSIS OF RESULTS
The data analysis shows similar behaviour between the two membranes with
respect to mass loss. The membrane MAPEPLAN TU, on average, loses about
0.24 g after 600 revolutions. The membrane MAPEPLAN TU WL, on average,
loses about 0.21 g after 600 revolutions. The two different membranes, while
showing comparable mass losses near the surface. However, they exhibit a
significantly different visual characteristic in the underlying black layer (see
Pictures below).

3. CONCLUSIONS
The resistance to abrasion assessment according to UNI EN ISO 5470-1 of
the two membranes MAPEPLAN TU and MAPEPLAN TU WL shows a similar TU WL 20 TU S 20
performance (similar mass loss). However, by applying the same mechanical
action (600 revolutions) to the MAPEPLAN TU WL it is far easier to detect
damage to the membrane surface.
Test results

UNDERGROUND
TECHNOLOGY
_6 BY MAPEI
 3.2.3. STANDARD AND TESTS
In order to provide CE certification, all MAPEPLAN products for tunnel
& underground structures are tested according to EN 13491 and
EN 13967 standards: Geosynthetic barriers Characteristics required for use
as a fluid barrier in the construction of tunnels and underground structures.

PROPERTY TO BE TESTED TEST METHODS

Physical Properties Thickness EN 1849-2

Mass per unit area EN 1849-2

Hydraulic Properties Water permeability (liquid tightness) EN 14150

Mechanical Properties Tensile strength ISO R 527

Elongation ISO R 527

Static Puncture EN ISO 12236

Burst Strength * EN 14151

Tear strength * ISO 34

Thermal Properties Low temperature behaviour (flexure) * EN 495-5

Thermal expansion ASTM D 696-91

Durability and Chemical Resistance Weathering * EN 12224

Micro organisms * EN 12225

Oxidation EN ISO 13438

Environmental stress cracking ASTM D 5397-99

Chemical resistance * EN 14414

Root penetration * CEN/TS 14416

Reaction to fire EN ISO 11925-2

*relevant to specific conditions of use

UNDERGROUND
TECHNOLOGY
BY MAPEI _7
CROSSRAIL PROJECT - Farringdon Station - London (UK)

UNDERGROUND
TECHNOLOGY
_8 BY MAPEI
UNDERGROUND
TECHNOLOGY
BY MAPEI _9
3.2.4. SYNTHETIC WATERPROOFING MEMBRANES SYSTEMS

MAIN WATERPROOFING SYSTEMS

CONSTRUCTION TYPOLOGIES
SYSTEM
DRAINED TUNNEL UNDRAINED TUNNEL FOUNDATION
(UMBRELLA SYSTEM) (FULL ROUND SYSTEM)
1L WS SYSTEM

1LP WS SYSTEM

2LP WS SYSTEM

Intermediate solutions are available and can be developed by MAPEI technical supervisors in order to supply
all technical requirements of a specific project.

1L WS - 1 LAYER / WATERSTOP
1L Single layer waterproofing membrane
WS Waterstop
Re-injectable hoses

1LP WS 1 LAYER / PROTECTION / WATERSTOP

1L Single layer waterproofing membrane
P Protection layer
WS Waterstop
Injection valve / Injection hose

2LP WS - 2 LAYER / PROTECTION / WATERSTOP (VACUUM SYSTEM)

2L Double layer waterproofing membrane
P Protection layer
WS Waterstop
Injection valve / Injection hose

UNDERGROUND
TECHNOLOGY
_10 BY MAPEI
1L WS - 1 LAYER / WATERSTOP

ADVANTAGE:
Primary compartmentalization

STRATIGRAPHY:
1. Substrate
2. Regularization layer - POLYDREN PP
3. Fixing disk- MAPEPLAN DISK
4. Waterproofing membrane - MAPEPLAN
5. Rebend connection - WATERSTOP
6. Back-up injection system (re-injectable hoses + end box) -
IDROSTOP MULTI + MAPEPLAN END BOX
7. MAPEPLAN drainage profile

6 3

UNDERGROUND
TECHNOLOGY
BY MAPEI _11
1LP WS 1 LAYER / PROTECTION / WATERSTOP

ADVANTAGES:
Primary compartmentalization
Injectable compartmentalization

STRATIGRAPHY:
1. Substrate
2. Regularization layer - POLYDREN PP
3. Fixing disk - MAPEPLAN DISK
4. Waterproofing membrane - MAPEPLAN
5. Protection layer (confinement of injection) -
MAPEPLAN PROTECTION
6. Injection valve + injectable hoses -
MAPEPLAN INJECTION VALVLE
7. Colleting - MAPEPLAN END BOX
8. Rebend connection - MAPEPLAN WATERSTOP

5 1
6
3
4

8
7

UNDERGROUND
TECHNOLOGY
_12 BY MAPEI
2LP WS - 2 LAYER / PROTECTION / WATERSTOP (VACUUM SYSTEM *)

ADVANTAGES:
Primary compartmentalization
Injectable compartmentalization
Testable before and after the realization of final lining (vacuum system)

STRATIGRAPHY:
1. Substrate
2. Regularization layer - POLYDREN PP
3. Fixing disk - MAPEPLAN DISK
4. Waterproofing membrane - MAPEPLAN
5. Separation layer MAPEPLAN SEPARATION LAYER
(or MAPEPLAN TU ST embossed membrane)
6. Waterproofing membrane (confinement of injection) - MAPEPLAN
7. Injection valve + injectable hoses + end box -
MAPEPLAN INJECTION VALVE
8. Protection layer- MAPEPLAN PROTECTION
9. Rebend connection - MAPEPLAN WATERSTOP

7
4
6 5

UNDERGROUND
TECHNOLOGY
BY MAPEI _13
VACUUM SYSTEM

COMPARTMENTALISATION / SECTORISATION
By using a double-layered system of PVC-P, in combination with waterstop,
injection valves, hoses, a tunnel waterproofing system can be divided and
compartmentalised into small independent watertight sections. The tunnel/
structure is therefore divided into manageable sections that can be treated
as individual entities.
This system allows us to test for water-tightness at locations suspected
of accidental damage, or in the case of leakage. Furthermore, the water
infiltrations would be limited to the single damaged section/compartment. Any
damage/leakage would remain localised, thus rendering easy rectification,
and thereby mitigating one of the major concerns with traditional PVC-P
applications. This compartmentalization forms this watertight control by
utilising the gap between the two waterproofing membrane layers. This gap
can be exploited to monitor the waterproofing system sealing and allows for
simple future repairs by resin injection.

VACUUM TESTING
The MAPEPLAN Vacuum waterproofing system allows us to objectively test
each section by removal of air between the two PVC-P layers (vacuum).
This testing can be performed several times during various critical stages of
construction:

- After installation of the waterproofing system.

- After installation of protection screed (horizontal surfaces).

- After installation of rebar (vertical surfaces)

- After the final concrete is cast.

Through the injection valves, it is always possible to access to the gap

between the two waterproofing membrane layers. Therefore vacuum testing
can be performed at any time, even many years after the construction has
been completed.
The opportunity to test the watertightness of the system during the different
construction steps is the best guarantee you could wish for the waterproofing
system. This type of test allows the contractor to easily detect the critical
construction phases. Consequently more attention can be paid to these
phases to ensure there are no repercussions.

UNDERGROUND
TECHNOLOGY
_14 BY MAPEI
 FUTURE REPAIRS
Through the control and injection valves, it is possible, once the leak has
been identified, to repair the waterproofing system. This is possible even
where the repair is inaccessible (slab / foundation walls). Reparation of the
waterproofing is carried out by injecting a low viscosity resin into the space
between the PVC-P layers sealing any damage that may have occurred
during the construction phases. This type of intervention, through injection,
is minimally invasive, and guarantees limited and rapid intervention times,
thereby avoiding significant interruptions to underground operations.

MAPEPLAN TU S MAPEPLAN
SEPARATION LAYER MAPEPLAN TT

CATANIA SUBWAY - Italy

UNDERGROUND
TECHNOLOGY
BY MAPEI _15
LAGONEGRO TUNNEL - Highway A3 Salerno-Reggio Calabria - Italy

UNDERGROUND
TECHNOLOGY
_16 BY MAPEI
UNDERGROUND
TECHNOLOGY
BY MAPEI _17
3.2.5 TECHNICAL DRAWINGS

1L WS - 1 LAYER / WATERSTOP

1LP WS 1 LAYER / PROTECTION / WATERSTOP

11

9
10 8

UNDERGROUND
TECHNOLOGY
_18 BY MAPEI
 1 Substrate (shotcrete)

2 Drainage layer
POLYFOND KIT

13 3 Regularization layer
POLYDREN PP

4 1st Synthetic waterproofing

membrane
MAPEPLAN / MAPEPLAN ST
4 3 5 Separation layer
MAPEPLAN SEPARATION LAYER
(compartment)

1 6 2nd Synthetic waterproofing

membrane
MAPEPLAN

7 Protection layer
MAPEPLAN PROTECTION

8 Re-injectable hoses
IDROSTOP MULTI

9 Waterbar
MAPEPLAN WATERSTOP
13
10 Injection valve
MAPEPLAN INJECTION VALVE
12
11 Hoses collecting box
7 MAPEPLAN END BOX
4 3 12 Protection screed

13 Final lining
1
14 Compartment overlap detail

Welding

UNDERGROUND
TECHNOLOGY
BY MAPEI _19
2LP WS - 2 LAYER / PROTECTION / WATERSTOP (VACUUM SYSTEM) +
DRAINAGE LAYER*

11

9
10 8
5 6
4 3

2LP WS - 2 LAYER / PROTECTION / WATERSTOP (VACUUM SYSTEM) +

DRAINAGE LAYER*

11

9
10 8
6
5
4 3

* to apply the waterproofing system in presence of water inflow

UNDERGROUND
TECHNOLOGY
_20 BY MAPEI
 1 Substrate (shotcrete)

2 Drainage layer
POLYFOND KIT
13
3 Regularization layer
POLYDREN PP
12
4 1st Synthetic waterproofing
membrane
7 MAPEPLAN / MAPEPLAN ST

2 5 Separation layer
MAPEPLAN SEPARATION LAYER
14 (compartment)
1
6 2nd Synthetic waterproofing
membrane
MAPEPLAN

7 Protection layer
MAPEPLAN PROTECTION

8 Re-injectable hoses
IDROSTOP MULTI

9 Waterbar
MAPEPLAN WATERSTOP

13 10 Injection valve
MAPEPLAN INJECTION VALVE
12
11 Hoses collecting box
MAPEPLAN END BOX
7
12 Protection screed
2 13 Final lining
14
1 14 Compartment overlap detail

Welding

UNDERGROUND
TECHNOLOGY
BY MAPEI _21
HIGH SPEED RALWAY MILAN-GENOA BASE TUNNEL - Italy

UNDERGROUND
TECHNOLOGY
_22 BY MAPEI
3.2.6 MAPEPLAN ACCESSORIES*

MAPEPLAN DRAINAGE MAPEPLAN DRAINAGE PROFILE

PROFILE Rigid PVC drainage profile to easy
connect the drainage system with
waterproofing membrane.

DRAINAGE BOARD POLYFOND KIT

POLYFOND KIT Embossed HDPE membrane
to drainage water allowing the
correct waterproofing system
application.

GEOTEXTILE * POLYDREN PP
POLYDREN PP HT Non-woven geotextile to be
*Different weights per square meters used as compensation, levelling,
available upon request
protection and filter layer.

FIXING DISK MAPEPLAN DISK

MAPEPLAN DISK PVC fixing element to apply the
waterproofing membrane and
provide a temporary support.

* TPO version available for all ancillary products

UNDERGROUND
TECHNOLOGY
BY MAPEI _23
WATERSTOP * MAPEPLAN WATERSTOP
MAPEPLAN WATERSTOPS PVC profile designed to
type 4/20 width 320 mm waterproof joints and creates
type 4/20 width 320 mm
compartment.
type 4/30 width 250 mm
type 6/20 width 600 mm
type 6/30 width 500 mm
type 6/30 width 400 mm

*Different waterstop profiles available on request

SEPARATION LAYER MAPEPLAN SEPARATION LAYER

MAPEPLAN SEPARATION Three dimensional extruded
LAYER polypropylene drainage core of
fused, entangled filaments.

PROTECTION MAPEPLAN PROTECTION

MAPEPLAN LAYER PROTECTION PVC membrane to protect the
MAPEPLAN waterproofing
membrane during the construction
operations.

RE-INJECTABLE HOSES IDROSTOP MULTI 11-19

IDROSTOP MULTI 11 * Double jacket re-injectable hoses for
*Accessories available multiple injections to seal joints and
replacing waterproofing system.

Related products:
Plastic Connectors, Ventilation Hoses,
Hot-shrinkage Hoses

UNDERGROUND
TECHNOLOGY
_24 BY MAPEI
INJECTION HOSES MAPEPLAN INJECTION TUBE
Injectable hoses to inject and seal joints
and replacing waterproofing system.

Related products:
Plastic Connectors, Ventilation Hoses,
Hot-shrinkage Hoses

INJECTION VALVE and MAPEPLAN INJETION VALVE

INJECTION TUBE PVC injection valve to inject resin
MAPEPLAN INJECTION VALVE in the compartment.

Related products:
Quick Fitting Connector 8-10 mm,
MAPEPLAN Injection Tube 6-8 mm

END BOX END BOX

MAPEPLAN END BOX Collecting box for hoses and
re-injectable hoses to allow
the connection of the pumping
equipment with the injection
system.

TRUMPET FLANGE MAPEPLAN CONIC COLLAR

MAPEPLAN MULTICOLLAR PVC ancillary product to
waterproof special detail.

UNDERGROUND
TECHNOLOGY
BY MAPEI _25
MAPEPLAN CONIC COLLAR MAPEPLAN COLLAR
PVC ancillary product to
waterproof special detail.

MAPEPLAN COLLAR MAPEPLAN MULTICOLLAR

PVC ancillary product to
waterproof special detail.

TAPE MAPEPLAN TAPE PVC 500 /220

MAPEPLAN TAPE PVC 500 Related product: ADESILEX PG4
Special PVC tape to realize
waterproofing membrane
termination and connection with
different waterproofing system.

METALSHEET and MAPEPLAN STRIP and TERMINAL

METALPROFILES STRIP PROFILE
MAPEPLAN METALSHEET Steel profiles covered with PVC
layer for special termination.

UNDERGROUND
TECHNOLOGY
_26 BY MAPEI
HYDROPHILIC SWELLION PROFILE Bentonite, acrylic, polyurethane and
IDROSTOP BTN EPDM based hydrophilic swelling profile.
IDROSTOP CV
IDROSTOP PTZ
IDROSTOP E

MTR - Hong Kong

UNDERGROUND
TECHNOLOGY
BY MAPEI _27
MTRC - Hong Kong

UNDERGROUND
TECHNOLOGY
_28 BY MAPEI
3.2.7 INSTALLATION TOOLS

Hot-air gun (art.A0800) Nozzle 40 mm (art.A0804)

Nozzle 20 mm (art.A0803)
Nozzle 5 mm (art.A0805)

Double welding machines Eletric engraver

(not included in delivery program) (not included in delivery program)

Brass roller (art.A0815) Engraver (art.A0809) Hook (art.A0810)

Toflon roller (art.A0808)
Rubber roller (art.A0807)

Welding jig Welding knife Vacuum bell

(not included in delivery program) (not included in delivery program) (not included in delivery program)

UNDERGROUND
TECHNOLOGY
BY MAPEI _29
RED LINE METRO STATION - Doha - Qatar

UNDERGROUND
TECHNOLOGY
_30 BY MAPEI
3.2.8 RISK MITIGATION: CHECK LIST FOR
WATERPROOFING (INSPECTION, WELDING TESTS)

1. ACCEPTANCE OF SUBSTRATE
Verify the compatibility of membrane flexibility
with shotcrete evenness
Substrate smooth, clean as specified

1 Substrate

b 5a
3m

Ra
0,
0,0
a

03 m
Ra

2. LEVELLING LAYER
Verify type (PP) and quality (500 g/mq) of the layer
(according to the substrate)
Verify that lapped are correct

1 Substrate

2 Regularization layer
POLYDREN PP

2
1

UNDERGROUND
TECHNOLOGY
BY MAPEI _31
3. FIXING ELEMENTS
Use an appropriate fixing element (preventive failure of the disk
prevent any possible laceration of the membrane)
Verify number and position of the disk

1 Substrate
2 Regularization layer
POLYDREN PP

3 Fixing element
MAPEPLAN DISK

2 3

4. WATERPROOFING MEMBRANE
Verify type (PVC-P), quality, length and mechanical characteristics
of the membrane
Verify that lapped are correct(overlap 10-12 cm)
Verify that membrane between fixing elements is not in tension

1 Substrate 4 Waterproofing membrane
MAPEPLAN
2 Regularization layer
POLYDREN PP

3 Fixing element
MAPEPLAN DISK

4 3
2

UNDERGROUND
TECHNOLOGY
_32 BY MAPEI
5. WATERSTOP
Verify Waterstops position
Verify that Waterstops are clean and free of residue
Verify welds with a hook

1 Substrate

4 Waterproofing membrane
MAPEPLAN
2 Regularization layer

POLYDREN PP 5 Waterstop
MAPEPLAN WATERSTOP
3 Fixing element
MAPEPLAN DISK

2 4 3

6. PROTECTION LAYER
Verify typologies, quality and thickness of the membrane

1 Substrate

4 Waterproofing membrane
MAPEPLAN
2 Regularization layer

POLYDREN PP 5 Waterstop

MAPEPLAN WATERSTOP
3 Fixing element

MAPEPLAN DISK 6 Protection layer

MAPEPLAN PROTECTION

5
6
2 4 3

UNDERGROUND
TECHNOLOGY
BY MAPEI _33
7. WELDING OF THE MEMBRANE
Verify that heating wedges are clean
Verify that membrane is clean
Verify the setup of welding machine: temperature, speed,
and pressure
Verify the correct realization of joints

8. WELDING INSPECTION

PARAMETER TEST METHOD FREQUENCY PASS/FALL CRITERIA

Coverage Visual Visual inspection to be carried out 100% coverage

continuously while the membrane is
applied

Double weld According to the supplier Every joint Pressure drop not to be greater
seam joints guidelines than 10% when a 2 bar pressure is
applied for 10 minutes

Single weld According to the supplier Every hand weld Hook test (*)
guidelines

Single weld According to the supplier Every patch Hook test and Vacuum bell test
guidelines (flatness permitting) (**)

UNDERGROUND
TECHNOLOGY
_34 BY MAPEI
I II III IV V
Visual inspection Manual Test Using a Hook Compressed air test Vacuum Bell Test Vacuum Pump Test
double welding joints/patch

I Visual inspection.
After welding, all seams should be visually inspected for good workmanship.
Special attention should be paid to T-joints, penetrations and flashings.

II Manual Test Using a Hook.

All hand-welded seams should be mechanically tested once they have
completely cooled. For this purpose use a hook (about 5 mm wide, with
blunted edges). Apply light pressure to the seam, taking care not scratch the
membrane. Mechanical testing is not a test for watertightness; it helps detect
seams that are not fully welded.

III Compressed air test - double welding.

The double-wedge machines produce two welded seams simultaneously. At
both ends of the double seam the channel between the two welds to be tested
is clamped shut and a manometer and needle installed. A foot pump is then
connected and the appropriate test pressure developed. The standard test
parameters are as follows: Test duration: 10 minutes; test pressure: 2 bars.
The seam is considered watertight if the initial pressure in the test channel
drops by not more than 10 % during the test period. The pressure values are
recorded, specifically the initial and final pressure.

IV Vacuum Bell Test - joints/patch

Test procedure:
Apply a soap solution over the seam edges within the range of the
vacuum bell.
Press vacuum bell over the area treated with soap solution and
build-up the vacuum (0.2 bar).
Visually check the seams under vacuum (bubbling soap solution
shows a leak).
Remove the vacuum bell and clean the seam with clean rags.
Any leaks must be rectified with a hand held welding gun and 20 mm
Silicon rollers at normal welding temperatures.

UNDERGROUND
TECHNOLOGY
BY MAPEI _35
IV Vacuum Pump Test.
This test is for testing each compartment prior to casting. To test and control
the membrane surfaces and relative welding of each compartment the
following procedure must be followed:
Identify and number the compartment to be tested.
For each compartment (200 to 250 m2), 4 to 5 valves need to be
installed. To one of these valves must be attached a hose and vacuum
pump. The remaining valves must be hermetically sealed (airtight).
Start the vacuum pump, run until the pressure drop is in the region
0.5-0.6 bar.
Wait until the reading remains stable (1 minute).
Record the initial test pressure (about 0.5-0.6 bar). Wait approximately
10 minutes and take note of the final pressure.
The test passes if the difference between the initial and final pressure
is lower than, or equal to 20%.
Through this vacuum test it is possible to check the integrity of the
waterproofing work. Also it is possible to identify and rectify defects with
minimal time and cost implications.

Hauge Tunnel - Istak Lonevag - Norway

UNDERGROUND
TECHNOLOGY
_36 BY MAPEI
 3.3. POST-INJECTION SYSTEM
WHERE TO USE
1. Sealing of punctual water inflow

2. Sealing of diffused water inflow

3. Raplacing of waterproofing system - Injection of compartments

(1LP / 2LP WS system) and re-injectable hoses (IDROSTOP MULTI)

4. Waterproofing and replacing of concrete cracks and joints

MAPEGEL UTT SYSTEM FOAMJET 260 LV

Three-component acrylic resin Two-component PU gel

Low viscosity and high permeation

Quick and controlled reaction time
Excellent elasticity
Excellent chemical resistance

IDROSTOP INGLOBATO NE GETTO

IDROSTOP IDROSTOP
IDROSTOP INIETTATO CON
DI embedded in concrete
CALCESTRUZZO injected
RESINA with resin
ACRILICA

UNDERGROUND
TECHNOLOGY
BY MAPEI _37
BACK-UP SYSTEM CONCEPT
Replacing waterstop and sealing joints with acrylic resin injection or
low viscosity PU gel (using re-injectable hoses).
Acrylic or low viscosity PU gel injection with valve inside
compartments made with synthetic waterproofing membrane.

1 Re-injectable hoses 3 Injection of acrylic resin

IDROSTOP MULTI 11 to repair the waterstop and seal

the construction joint
2 Construction joint MAPEGEL UTT SYSTEM

3 1

1 Compartment
4 Injection hoses
2 Acrylic resin ti inject the 5 Collecting hoses box
compartment MAPEPLAN END BOX
MAPEGEL UTT SYSTEM

3 Injection valve
MAPEPLAN INJECTION VALVE

4 3
1 2

UNDERGROUND
TECHNOLOGY
_38 BY MAPEI
3.4. SPRYABLE WATERPROOFING MEMBRANE AND
SYNTHETIC WATERPROOFING MEMBRANE

3.4.4. SPRYABLE WATERPROOFING MEMBRANE AND PVC

MAPELASTIC TU SYSTEM is integrated and compatible with PVC

waterproofing membrane (MAPEPLAN).
Detail: overlap between PVC membrane (MAPEPLAN) and MAPELASTIC TU
SYSTEM.

LTSCHBERG TUNNEL - Switzerland

UNDERGROUND
TECHNOLOGY
BY MAPEI _39
RED LINE METRO STATION - Doha - Quatar

UNDERGROUND
TECHNOLOGY
_40 BY MAPEI
MAPEI UTT
Underground Technology Team

UTT TECHNICAL ASSISTANCE PROVIDES:

Great technical skills according to deep knowledge of products,
production phases and construction systems;
Assistance during construction and design phases, in order to focus on
the correct products and technical solutions;
Global intervention, 24 hours per day and 365 days per year;
Production optimization and costs reduction.

THE WORLD OF UTT

SHOTCRETE TECHNOLOGY
MECHANIZED TUNNELING PRODUCTS
DRILLING AND GROUND CONSOLIDATION PRODUCTS
INJECTION SYSTEMS
WATERPROOFING SYSTEMS
PAVEMENT PRODUCTS
TUNNEL MAINTENANCE, REHEABILITATION AND COATING PRODUCTS

SUPPLIER OF ...

PRODUCTS SYSTEMS INNOVATION TECHNICAL

SUPPORT
UNDERGROUND
TECHNOLOGY
BY MAPEI _43
 C.P. MK6482030 (GB) 3/16
www.utt-mapei.com
hq.utt@utt.mapei.com

HEADQUARTERS
MAPEI SpA
Via Cafiero, 22 - 20158 Milan
Tel. +39-02-37673.1
Fax +39-02-37673.214
Internet: www.mapei.com
E-mail: mapei@mapei.it /mapeispa