Tunnelling solutionsHigh performance technology for concrete, waterproofing and repairs

Company background

With more than 80 years’ experience in developing solutions for the construction, structural and civil engineering markets, Fosroc has become world-leader in this field, building a reputation for innovation, quality, customer focus and expert technical support.

Supplied and supported from an extensive network of administrative and manufacturing facilities across Europe, the Middle East, India, North and South Asia, Fosroc products and services offer solutions for construction, infrastructure and utilities markets. Our international reach is further extended through approved distributorships and licensee partners across the globe, which Parchem Construction Supplies is the exclusive licensed manufacturer and distributor of Fosroc products in Australia and New Zealand.

Parchem’s range of Fosroc products include:-

Concrete admixtures Surface Treatments Grouts & anchors Waterproofing Joint sealants Concrete repairs Surface coatings Industrial flooring

This comprehensive product offering is backed by expert technical and sales support to ensure that you receive the most effective and efficient solutions. Our tailored project solutions include:-

Project specifications CAD and BIM detailing Technical support Site support CPD Seminars

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Technology developmentsDue to the growing concern from environmental issues and the decrease of available urban land, the demand for tunnel construction is on the increase. Alongside these demands, the technological developments in construction methods, applications and products have shown substantial progress in recent years.

Searching for efficiencyIn today’s tunnel construction market, clients and contractors are searching for new ways to be more efficient which will result in tangible cost savings. Fosroc recognise this and have developed their business to give guidance to Engineers and Contractors, providing them with the tolls to choose the best possible system solutions, specifically tailored to meet their individual project requirements. Fosroc are constantly improving the technology performance of their products, striving to provide solutions that reduce tunnel construction times, maintenance and safety concerns whilst simplifying installation methods and creasing long term durability.

The Fosroc SolutionFosroc Tunnelling can provide you with customised solutions which include;

On-site support Our site specialists advise on the most efficient and economical solution for your project in close collaboration with the

project site personnel. Supported by regional development and research centres, our tailored solutions are innovative, practical and economical.

Project specific mixes using admixtures that deliver low hazard, high productivity, long term durable concrete and shotcrete.

Multi-system choices for waterproofing, grouting, repairs, injection resins, waterstops, drainage membranes, polypropylene fibres, release agents and surface retarders.

Accelerators for high performance shotcrete. Technical specifications, testing and reports.

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Shotcrete

Latest tunnelling methods adopt shotcrete to control surface deterioration of the surrounding rock in a number of ways. The most common method is to prevent the loosening of the substrate and to preserve the in situ moisture content of certain types of rock.

Shotcrete can be applied without reinforcement, but usually it is reinforced with steel mesh or more commonly with fibres. Fosroc’s range of innovative accelerators enable the shotcrete to adhere to the substrate, even in overhead applications, and develop high early strength for the consolidation of the rock structures. It is usually installed with other forms of rock support, such as rock-bolts, anchors and dowels or in severe cases with steel sets (arches). When shotcrete and rock reinforcement are used together, they form a composite support system with reinforcement supporting the rock mass as a whole and shotcrete layer maintaining the integrity of the surface and rock reinforcement.

Shotcrete is straightforward to apply but consideration should be given to the correct mix design, additives (hydration control, fast setting agents etc.) and which equipment is required. Nozzle handling is also a key factor for successful applications. Fosroc is your ideal partner to provide assistance from design phase through to on-site support, selecting from their extensive range of shotcrete admixtures.

Typical applications; Road and rail tunnels Hydropower tunnels Concrete repair Water channels Slope stabilization Artificial rock

Product Benefits

Sprayset HBP Low rebound – less wastageHigh build up with minimal slump – faster applicationSafe to handle

Sprayset SL Rapid set – fast applicationMinimum rebound – less wastageExcellent for overhead surfaces

Fibrecrete FR Reduced ‘shrapnel’ effectPP fibres therefore no corrosion problems

Sprayset HBL42 Alkali-free and low dust emission – improved working environmentRapid set – fast applicationLow rebound – less wastage

Sprayset HBL44 Alkali-free and low dust emission – improved working environmentHigh performance rapid setting, low rebound, economic accelerator

Fibrecrete ST750 PP fibres therefore no corrosion problems>750J energy absorptionEconomical system

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Waterproofing

Product Benefits

Sprayset HBP Low rebound – less wastageHigh build up with minimal slump – faster applicationSafe to handle

Sprayset SL Rapid set – fast applicationMinimum rebound – less wastageExcellent for overhead surfaces

Fibrecrete FR Reduced ‘shrapnel’ effectPP fibres therefore no corrosion problems

Sprayset HBL42 Alkali-free and low dust emission – improved working environmentRapid set – fast applicationLow rebound – less wastage

Sprayset HBL44 Alkali-free and low dust emission – improved working environmentHigh performance rapid setting, low rebound, economic accelerator

Fibrecrete ST750 PP fibres therefore no corrosion problems>750J energy absorptionEconomical system

Most major decisions for tunnelling projects begin with adequate knowledge of the specific ground conditions and how to design the structure around these. The method of dealing with water from the surrounding ground is one of the important considerations, and if not assessed properly and the subsequent waterproofing system not applied correctly the first time, will cause leakages resulting in expensive remedial costs.

Fosroc have extensive worldwide experience in the waterproofing of below-ground structures and can offer several solutions for the tunnel sector from their broad portfolio. Fully bonded waterproofing systems provide the highest level of waterproof protection. These can be either in sprayed form or by pre-applied membrane.

For assistance in the choice of the best waterproofing system for your particular tunnel project please contact your local Fosroc office.

Application Product Benefits

Fully bonded waterproofing Proofex Engage Assured waterproofing due to mechanical bond to fresh concreteExcellent non water-tracking performanceEasy, quick installation

Fosroc Polyurea WPE Shortened construction times due to rapid setting propertiesSpray-applied seamless system

Loose-laid waterproofing Proofex PGP Established waterproofing methodHigh puncture resistance and elongation

Concrete joints Supercast PVC/SW Basic polymer swellable waterstops giving excellent long term wet/dry cycle durabilityEconomical PVC profiles

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Parchem’s portfolio of products provides solutions for TBM, cut/cover and drill/blast tunnel methods giving improvements to performance and cost effectiveness through trouble-free shotcreting, waterproofing and crack repairs.

For information on all Fosroc products please visit www.parchem.com.au where technical data including TDSs and SDSs can be downloaded.

Technical

Data

Sheet

Page 1

March 2014

High strength, low shrinkage, high build

spray applied repair mortar

Uses

For the reinstatement of large areas of concrete and for

small, localised patch repairs in areas such as sea walls

bridge decks and piers, tunnels, sewer pipes, etc.

Advantages

High build

High early strength

Low drying shrinkage values

Low rebound

Chloride free

Description

Guncrete E is supplied as a ready to use dry powder

for use with standard dry spray gunite or shotcrete

equipment. The material is formulated to produce a high

build, material which can be applied by standard spraying

techniques.

Technical Support

Parchem offers a comprehensive range of high performance,

high quality construction products. In addition, Parchem

offers a technical support service to specifiers, end-users

and contractors, as well as on-site technical support.

Design Criteria

Guncrete E is designed for vertical, overhead or horizontal

applications. It can be applied in sections from 10 mm up to

150 mm depending on substrate geometry. The material

should not be applied at less than 10 mm thickness.

Specification Clauses

Steel reinforcement primer

The steel reinforcement primer shall be Nitoprime Zincrich, a

single component zinc-rich epoxy resin.

The primer shall be an ‘active’ type, capable of avoiding the

generation of incipient anodes in the immediately adjacent

locations.

Repair mortar

The shrinkage-compensated reinstatement mortar

shall be Guncrete E, a single component cement-based

blend of powders to which only the site-addition of clean

water shall be permitted. The cured mortar shall achieve >45

MPa compressive strength at 28 days. Drying shrinkage

measured to ASTM modified 23°C/RH50% shall be not

greater than 500 microstrain at 7 days and 700 microstrain at

28 days.

Fosroc® Guncrete ETechnical

Data Sheet

Page 1

March 2014

High performance, light-weight, very

low shrinkage, patch repair mortar

UsesFor the reinstatement of large areas of concrete where low

permeability characteristics, lowest drying shrinkage

characteristics is required. Renderoc HB25 has been

specifically engineered for vertical and overhead repair work

where its lightweight nature makes it ideal. The mortar can

also be used for small, localised patch repairs.

Where higher compressive strengths are required as well as

low permeability characteristics, Renderoc HB40, Renderoc

HB70 or Renderoc LA55 should be used.

Important Note 1: When Renderoc HB25 is

used in conjunction with Impressed Current

Cathodic Protection or Norcure Realkalisation

and Desalination methods, the substrate

bonding primer should be an OPC: Water

slurry mixed at a 2:1 ratio.Polymer bonding agents should not be used.

No steel primer should be applied. Please

refer to Parchem for further advice.Important note 2: Renderoc HB25

is suitable for use with Galvashield

XP incipient anode protection, with

a resistivity <15,000 Ω cm @ 28

days.

DescriptionRenderoc HB25 is supplied as a ready to use blend of dry

powders , requiring only the site addition of clean water to

produce a highly consistent, lightweight repair mortar. It is

based on Portland cements, graded aggregates, lightweight

fillers and chemical additives which provide a mortar with

good handling characteristics while minimising water

demand. The low water requirement ensures good strength

gain and long-term durability.Technical SupportParchem offers a technical support package to specifiers,

end-users and contractors, as well as on-site technical

assistance.Advantages Maximum compatibility with concrete with a compressive

strength in the range 15 - 30 MPa Polymer-modification provides extremely low permeability

to water, carbon dioxide and chlorides

Exceptional system of shrinkage compensation provides

long-term dimensional stability Lightweight formulation enables extra high-build - fewer

cold joints Frequently obviates the need for formwork

Can be applied quickly and efficiently by wet spraying

One component, pre-bagged to overcome site-batched

variations Contains no chloride admixtures

Suitable for internal and external applications

Design CriteriaRenderoc HB25 exhibits a series of performance

characteristics designed to achieve maximum compatibility

with concrete with a compressive strength greater than

15 MPa.Renderoc HB25 has been specifically engineered for vertical

and overhead repair work. It can be applied in sections up to

80 mm thickness in vertical locations and up to 60 mm

thickness in overhead locations in a single application and

without the use of formwork. Thicker sections can be

achieved by the use of formwork or can be built up in layers.

Deep pockets can sometimes be filled in a single application

dependent on the configuration of the pocket and the volume

of exposed reinforcing steel.Build can be dramatically increased by wet spraying. Typical

achievable thicknesses are 175 - 250 mm vertically and 150

- 200 mm overhead, although this will depend on substrate

profiles and the distribution of steel reinforcement. Consult

your local Parchem sales office for further information.

The material should not be applied at less than

10 mm thickness.Where higher compressive strengths are required, Renderoc

HB40, Renderoc HB70 or Renderoc LA55 should be used.

Specification ClauseHigh-build concrete reinstatement mortar

The reinstatement mortar shall be a single component

polymer-modified, cement-based blend of powders to which

only the site addition of clean water shall be permitted. It

shall be manufactured to achieve maximum compatibility

with reinforced concrete with a compressive strength greater

than 15 MPa and as a consequence, shall exhibit the

following characteristics when tested to the standards

shown.

Fosroc® Renderoc HB25

Cost-effective solutions World class customer

service International coverage Understanding customer

needs Tailored products Innovative technology

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Application Product BenefitsPrecast concrete Auracast PC admixtures Excellent rheology at low w/c ratios leading to high quality

finish

In-situ concrete Auramix PC admixtures Increased early & long term strength of concrete Reduced bleeding and segregation Reduced overall application costs

Conplast SP Superplasticiser admixture

Reduced w/c ratio Improved strength development Improved fresh and hardened concrete properties

Conplast HC Hydration control admixture

Improved flexibility in site logistics and application

Underwater concrete Conplast UW

Conbextra UW

Minimises washout of concrete placed underwater

Fibre reinforcement and passive fire protection

Fibrecrete PP fibres No HSE concerns No long term corrosion issues Reduced equipment wear – less downtime and maintenance costs

Concrete repair Renderoc range of hand, spray or flow applied mortars

Fast setting, high strength, high-build, low shrinkage

Crack repairs Nitofill LV Resin injection – dry repairs

Grouting Conbextra range Cementitious and resin systems Thixotropic and pumpable grades

Parchem’s tunnel solutions range

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Parchem Construction Supplies Pty Ltd7 Lucca Road, Wyong NSW 2259Phone: 1300 737 787www.parchem.com.auABN 80 069 961 968 05

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www.parchem.com.au

Superior Service Throughout AustraliaWith trade stores and warehouses throughout Australia, Parchem is able to offer a superior level of service to customers in all regions of the country.

Single Source SupplierParchem range of products gives you the security of dealing with a single sup-plier for a complete range of compatible solutions to meet the total needs of your project.

ISO 9001 Quality AssuranceWith its manufacturing facilities fully accredited to ISO 9001, Parchem offers its customers the assur-ance of independently audited quality systems.