Concrete Waterproofing with Crystalline Technology ...seaog.org/waterproofing.pdf · Report on Chemical Admixtures • PRAN – Permeability Reducing Admixtures ... Crystalline waterproofing

Concrete Waterproofing

with CRYSTALLINE TECHNOLOGY

Xypex Chemical Corporation is a Registered Provider with the American Institute of Architects Continuing Education Systems. Credit earned on completion of this program will be reported to CES Records for AIA Members.

Certificates of Completion for non-AIA members are available on request.

This program is registered with the AIA/CES for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner of handling, using, distributing, or dealing in any material or product.

Questions related to specific materials, methods, and services will be addressed at the conclusion of this presentation.

1. Understand how crystalline technology works with concrete to provide high performance waterproofing characteristics.

2. Explain the difference between porosity, permeability and the mechanics by which water is absorbed through concrete structures.

3. Discuss how crystalline waterproofing technology works, improves the durability of concrete structures and reduces maintenance.

4. Identify the appropriate crystalline technology product applications for various types of concrete construction.

5. Analyze how crystalline technology admixtures can impact building life cycle and project construction costs.

After this presentation you should be able to:

Learning Objectives

T H E N AT U R E O F C O N C R E T E

Most Widely Used Building Material

The Nature of Concrete

Composed of a mixture of rock, sand, cement and water

To be workable, more water than needed for cement hydration is used

Excess water bleeds out and leaves a network of capillaries and pores

As it dries, concrete shrinks and changes volume causing micro and macro cracks


Composition

Calcium hydroxide and other by-products of cement hydration precipitate in concrete voids


Composition

• POROSITY - Refers to the amount of holes or voids left in the concrete. It is expressed as a percentage of the total volume of material.

• PERMEABILITY – Is the ability of liquid water under pressure to flow through a porous material. It is expressed as a permeability coefficient (D’Arcy’s Coefficient)

Permeability is a good indicator of the quality and durability of the concrete.

Porous and permeable concrete will allow the intrusion of water, chlorides, sulfates and carbon dioxide which can lead to deterioration


Porosity & Permeability


Porosity


Capillary Pores

Capillary voids are essentially the residue of the originally water filled spaces - this is the primary path by which water and other aggressive ions can penetrate into the concrete matrix, and cause durability problems (i.e. rebar corrosion)

5000xmagnification

Micro CracksT H E N AT U R E O F C O N C R E T E

Caused by structural, thermal, drying and plastic shrinkage

Macro CrackingT H E N AT U R E O F C O N C R E T E

Entrapped Void 1,000 µm to 10,000 µm

Crack 100 µm to 3,000 µm

Micro Crack <0.1 µm to 100 µm

Transition Zone 10 µm to 50 µm

Capillary Pore 0.01 µm to 1 µm

(0.000039 inches)

PermeableT H E N AT U R E O F C O N C R E T E

Concrete Deterioration

Water IngressC A U S E S O F C O N C R E T E D E T E R I O R AT I O N

Water penetrates concrete through its porosity, cracks and other voids

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Sulfate Attack

Sulfate salts in solution enter the concrete through the open capillary structure of the concrete substrate causing an expansive reaction which attacks the cementing materials

Water carries sulfates into capillary pores

C A U S E S O F C O N C R E T E D E T E R I O R AT I O N

Water &Chemicalingress

Corrosion of reinforcing steel

• Caused by ingress of water

• Accelerated by chlorides from de-icing salts or a marine environment

• Rusting reinforcing steel expands to 8 times its original size

• Creates pressures exceeding concrete’s tensile strength

Corrosion of Reinforcing SteelC A U S E S O F C O N C R E T E D E T E R I O R AT I O N

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Freeze/Thaw Damage

• Water penetrates concrete pores

• As it freezes it expands up to 9%

• Pressure exceeds tensile strength

• Cavity will dilate and rupture

C A U S E S O F C O N C R E T E D E T E R I O R AT I O N

Traditional Solutions

T R A D I T I O N A L S O L U T I O N S

Liquid Membranes

• Installation errors• Easily punctured during

backfill• Specialty applicator,

equipment and expertise required

• Breach affects integrity of entire system

• Requires adequate cure of concrete before application

• Can require up to 2 weeks before backfilling

• Deteriorates over time• High carbon footprint• Requires smoothed surface

Disadvantages

• Deteriorates overtime• Prone to Installation errors• Breach affects integrity of

entire system• Failure repair requires

excavation• High carbon footprint• Can be ineffective in the

presence of contaminated water

• Requires dry substrate for 28 days before application

• Requires smoothed surface for application

Pre-Formed MembranesT R A D I T I O N A L S O L U T I O N S

Disadvantages

• Installation errors

• Repair after failure almost impossible

• Can be ineffective in the presence of contaminated water

• Requires adequate coverage and confining pressure for water-gel reaction to be effective

• Labor intensive – difficult to install

• Pre-hydrating in wet conditions

• Requires Smooth surface

BentoniteT R A D I T I O N A L S O L U T I O N S

Disadvantages

Crystalline Waterproofing Technology

How It WorksC R Y S TA L L I N E W AT E R P R O O F I N G T E C H N O L O G Y

+Crystalline Waterproofing Chemicals

Calcium Hydroxide and other by-products of cement hydration / un-

hydrated cement particles

=

Non-soluble crystalline formation permanently fixed within the

concrete’s pore structure

C R Y S TA L L I N E W AT E R P R O O F I N G T E C H N O L O G Y

How It Works

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How It Works

Ca(OH)2 is available to react with crystalline chemicals

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How It Works

Chemical reaction initiates crystalline formation

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How It Works

Fully developed crystalline formation fills void space

• Integral waterproofing - cannot be punctured or damaged at the surface

• Crystalline waterproofing will withstand high hydrostatic pressure from both the positive and negative side

• Unaffected by marine exposure, sulfite/alkali or soils contaminated by previous use

• Crystalline waterproofing is highly resistant to chemicals

• Crystalline waterproofing is unaffected by humidity, ultraviolet light and oxygen levels


How It Works

Advantages

• Admix• Coating• Dry-Shake

Crystalline Waterproofing can be installed in one of three ways:

How It WorksC R Y S TA L L I N E W AT E R P R O O F I N G T E C H N O L O G Y

Proven Performance

P R O V E N P E R F O R M A N C E

Independent Testing


Permeability Testing

US Army Corps of Engineers CRD-C48 and EN 12390-8 ‘though-put ‘ or ‘depth of penetration’ tests are best at demonstrating the effectiveness of crystalline waterproofing technology

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Untreated control sample had average 84 mm of water penetration. Crystalline coated sample had average 6 mm of water penetration. Hydrostatic pressure equivalent to 224 ft of hydraulic head

Bautest, DIN 1048, Germany, 1980


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Taywood Engineering, CRDC C48-73, Singapore

Six crystalline waterproofed samples and six control samples were subjected to incremental pressures up to 7 Bar (224 feet of head of water) over a 10 day period. After 5 days the untreated samples started to leak while the treated samples were completely waterproof


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Compressive Strength TestingP R O V E N P E R F O R M A N C E

Kleinfelder Laboratories, San Francisco, California, USA

0.55 w/cm ratio38% Slag Concrete

0.55 w/cm ratio38% Slag Concrete 1.6% Crystalline Admixture

Increased time to corrosion by a factor of 5


Chloride Diffusion Testing

• Crack Sealing• Sulfate attack • AAR/ASR • Carbonation• Acid Resistance• Hot and Cold Environments• Freeze-thaw


Additional Testing

Extensive testing has also been done for the following:

PRAN’s vs PRAH’s

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ACI 212-3R-10Report on Chemical Admixtures

• PRAN – Permeability Reducing Admixtures (Hydrophobic Liquids) for concrete not exposed to hydrostatic pressure conditions

• PRAH – Permeability Reducing Admixtures (Hydrophilic Crystalline Technology) for concrete exposed to hydrostatic conditions


Case StudiesLEED Contributing Technology

Reduced Impact on the Environment

Non-Toxic No VOCs

Natural Chemistry

Lower Resource

Consumption

Biodegradable Packaging

Recyclable

L E E D C O N T R I B U T I N G T E C H N O L O G Y

Sustainability

• MR Credit 2.1 Waste Management

• EQ Credit 4.2 Low Emitting Materials Paints and Coatings

• ID Credit 1-1.4 Innovation in Design


Sustainability

Contributes Towards LEED Credits

• Protecting Against Corrosion of Reinforcing Steel• Improving Freeze/Thaw Durability• Mitigating ASR attack• Resists Sulfate Attack• Enhancing Resistance to a Variety of Corrosive and

Caustic Environments


Sustainability

Extends Service Life of Concrete Structures by:

Installation MethodsInstallation Methods

Admixture

Available in easy to use, pre-measured soluble bags

• Uniform distribution throughout the concrete and structure

• Reduces shrinkage cracking and increases compressive strength

• Same crystalline structure as the coating

• Significantly reduces installation costs

I N S TA L L AT I O N M E T H O D S

• Applied as a highly concentrated cement slurry solution• Crystalline chemicals diffuse through water in saturated substrate• Can penetrate up to 12 inches deep• Ideal for ‘negative side’ waterproofing

CoatingI N S TA L L AT I O N M E T H O D S

Application

• Application rate is 1.5 lbs of material per sq. yd. (6 sq ft per lb)

• Applied by brush, 100 sq. ft/hr

• Hopper gun, 500 sq. ft/hr

• Specialized spray equipment, 1200 sq. ft/hr

CoatingI N S TA L L AT I O N M E T H O D S


•Non – Moving Joints Only•Wall / Slab or Slab / Slab•Hydrostatic Conditions

•2 levels below grade•Constant water contact

Use these details in conjunction with joint waterstops

Coating

Joint Detailing

Dry Shake

Crystalline chemicals are incorporated into the concrete surface during finishing (Also available with added floor hardener)


Rout out Crack

Apply Slurry Coat

Pack Rout

Crack and Joint Repair• Active Water Flow or Dry• Positive or Negative Side• Will often give full depth repair through

diffusion and crystal growth• Will reheal if cracks again in future

Patching & RepairI N S TA L L AT I O N M E T H O D S

Applications

A P P L I C AT I O N S

Crystalline Waterproofing Applications

Elevator PitsWater Retention TanksFire Suppression Tanks

Foundation WallsPlantersRetaining Walls

High Water Table - Adjacent to Lake Mendota800 ft long utility tunnel Crystalline waterproofing admixtureCoating applied to construction joints

Utility TunnelsW i s c o n s i n I n s t i t u t e f o r M e d i c a l S c h o o l , M a d i s o n , W I


600 room LEED certified hotelDowntown Denver next to the convention center1,500 cubic yards for parking garage foundation walls and elevator Pits


Underground Parking GarageE m b a s s y S u i t e s H o t e l , D e n v e r, C O

Cast –in-place and shotcrete4,500 cubic yards Foundations walls and aquarium tanks


Foundation Walls and SlabsC a l i f o r n i a A c a d e m y o f S c i e n c e , S a n F r a n c i s c o , C A

Shotcrete Foundation Walls

24,000 lbs used in slab and blindside shotcrete foundation wallsSlurry coating applied on construction joints between shotcrete sections


8 5 t h A v e A p a r t m e n t s , R e n t o n , W A


Secant Pile Foundation ConstructionP a r k R e g i s H o t e l , S i n g a p o r e

Joint line sealing with crystalline enhanced hydraulic cement followed by two coat treatmentCrystalline admixture was also used in the basement slab


Fire Suppression & Water RetentionA l l e y 111 , B e l l v u e , W A

Crystalline admixture used on blind-side formed shotcrete water detention vault and cast-in-place fire suppression tanks eliminating need for liners and reducing on site waste

Foundation Slab Pile CapsA P P L I C AT I O N S

S a c r a m e n t o K i n g s A r e n a , C A

300 pile caps Up to 15’ x 20’ in sizeCrystalline slurry coating applicationInstalled while pile cap concrete still wet

Underground ParkingR i z e B u i l d i n g , Va n c o u v e r , B C

500 cubic meters (approx 550 cu yds)Below grade exterior walls and slabElevator pits 30 Mpa (3,000 psi) fly-ash mix


Tilt-Up WallsTo r r a n c e H o s p i t a l , To r r a n c e , C A


Crystalline admix used in 33,300 square feet of decorative tilt up wall surface with light sandblast finishNo paint or water repellent requiredLEED bronze certified

Water Retention StructuresA P P L I C AT I O N S

P o t a w a t o m i C a s i n o , M i l w a u k e e , W I

2,750 cubic yards of cast-in-place concrete with crystalline admixtureCrystalline slurry and dry-pack seal installed at floor/wall joints

Parking Structures

1,200 cubic yards 400 car parking deck and balconiesLEED Silver building

P a s e o N u e v o O f f i c e C o m p l e x , A l b u q u e r q u e , N M


3,600 cubic yards 70% slag replacement concrete mix with 2% crystalline admixCompatible with high fly-ash or slag replacement mixesLEED Certified Building

Green Walls111 U n i v e r s i t y A v e , P a l o a l t o , C A


Crystalline waterproofing admixture was used in the shotcrete and cast-in-place concrete for the new Sea Lion Sound exhibit at the St. Louis ZooWinner of the AZA Exhibit Award for 2013

Zoo and Aquarium ExhibitsS t . L o u i s Z o o S e a L i o n E x h i b i t


Slabs on Grade

Dry-shake crystalline waterproofing installation110,000 sq ft slab-on-gradeReplaced originally specified under-slab bentonite due to soil conditions

D u r a c e l l D i s t r i b u t i o n F a c i l i t y, C l e v e l a n d , T N


Replaced membrane system in second phase

Significantly reduced construction costs and accelerated schedule by three months

Foundations in Challenging ConditionsT h e a t r e s o n t h e B a y, S i n g a p o r e


• Crystalline waterproofing penetrates deep into concrete

• Does not depend on surface adhesion like barrier systems

• Will not blister or peel on a negative side

Elevator PitsP i s n o B e a c h , C A

Negative Side Application


Coating, Admix & Dry-Shake Application

All three crystalline application methods were used in the construction of this reservoir :

• Dry-shake for the slabs• Coating for 22” thick walls• Admixture for the lid on which

recreation courts would be placed

C h e r r y H i l l R e s e r v o i r , S e a t t l e , W A


Thank you for your time.Questions?

The American Institute of ArchitectsContinuing Education Systems Program

Contact InformationLes Faure, Tel: 800-961-4477

This presentation is protected by U.S. and International copyright laws. Reproduction, distribution, display and use of the presentation without written permission of the speaker is prohibited.

© Xypex Chemical Corporation 2008

Documents

Concrete Waterproofing with Crystalline Technology ...seaog.org/waterproofing.pdf · Report on Chemical Admixtures • PRAN – Permeability Reducing Admixtures ... Crystalline waterproofing