MASTERSEAL 345

Design Guideline
INDEX
1. INTRODUCTION
2. DOCUMENTATION: SPECIFICATION & METHOD STATEMENT
3. DESIGN PRINCIPLE
4. APPLICATIONS
4.1. TUNNEL EXHIBITING LOCAL WATER INGRESS
4.2. TUNNEL WITH WATER INGRESS AT ZONES WITH LOCALIZED WEAKNESS
4.3. TUNNEL WITH FULL CIRCUMFERENTIAL WATER PROOFING
4.4. SPRAYABLE WATERPROOFING MEMBRANE UNDER COMPRESSION E.G.
FOR CHANNELS, BASINS, WATER TRANSFER TUNNELS
5. INSTALLATION
5.1. KEY REQUIREMENTS FOR MASTERSEAL345
5.2. METHOD STATEMENT
6. MECHANICAL, CHEMICAL, BIOLOGICAL PROPERTIES
7. ESTIMATE OF MATERIAL CONSUMPTION AND PERFORMANCE
8. SUGGESTED BOQ ITEM SPRAYED MEMBRANE:
9. REFERENCE LIST
10. APPENDIX

Prepared by: Dr. Wolfgang Aldrian, June 2009

1.

INTRODUCTION
MASTERSEAL 345 is a sprayable waterproofing membrane. This guideline details
the MASTERSEAL spray applied waterproofing system and the areas of application
for tunnels and other underground works. Four typical scenarios are shown, allowing
the designer to assess his particular situation and derive benefit from the unique
properties of this waterproofing system. For example, the MASTERSEAL composite
lining can be used as composite lining or as replacement of the inner cast concrete
lining for complex 3D geometries. Other applications particularly benefit from the
bonding of MASTERSEAL to one or both layers in a composite design, which
prevents lateral migration of water along the waterproofing interface.

2.

DOCUMENTATION: Generic Specification and METHOD STATEMENT

A Generic Specification has been given previously for designers and contractors and
is available on request [1], a Table of performance properties is given in Appendix A.
Method Statements for substrate conditions, installation environment, properties of
the cured membrane, guidelines for consumption and quality assurance are available
to supplement this document. More details for the application are given in the BASF
Method Statement Application of MASTERSEAL 345 Sprayable Membrane [2].

3.

DESIGN PRINCIPLE
MASTERSEAL 345 sandwiched between concrete or sprayed concrete elements is
a thin, watertight, crack bridging layer that is fully bonded on either side. The
resultant application of the MASTERSEAL 345 System constitutes typically a 3-layer
composite structure.

Figure 1:

Functional principle of a sprayed waterproofing membrane MASTERSEAL

345 bond on either side. Cores drilled from a composite lining are shown.

A composite lining comprising a MASTERSEAL 345 layer can be designed as a

watertight structure against limited water pressure (MASTERSEAL 345 was tested
successfully at 20 bar pressure) or as structure for laminar conduction of seepage
water (umbrella).
MASTERSEAL 345 sprayed membrane shall normally be coated with sprayed
concrete at the inner side. For tunnels, the structure of the composite lining shall be
designed assuming a bond of >0.5MPa between layers.
4.

APPLICATIONS
4 design cases can be distinguished:
-

Tunnel case 1: Local water ingress at joints (or similar) in a competent,

impermeable rock mass.
Tunnel case 2: Laminar ingress of water in permeable soil or rock mass,
including measures for permanent elimination of water pressure (umbrella).
Tunnel case 3: Water-proof composite featuring full circumferential lining in
a rock mass (or soil) of low permeability or with temporary ground water
lowering.
Other cases: The composite lining is acting under compression, e.g.
providing full containment, as a water pond, using composite sprayed
concrete lining.

4.1. TUNNEL EXHIBITING LOCAL WATER INGRESS

MASTERSEAL 345 composite lining together with localised grouting of seeping
joints constitutes an effective water proofing system for a tunnel in rock mass with
low to moderate jointing.
Installation Sequence:
- Before application of MASTERSEAL 345, local seepage water is typically
drained via short drill holes, wedge packers and hoses.
- MASTERSEAL 345 is applied to the full surface and left to cure.
- The drill holes are grouted with a low viscosity resin, e.g. acrylic gel, thus
sealing water seepage at joints and improving rock properties.
- Finally, the internal sprayed concrete can be applied directly onto the
waterproofing membrane. Due to strong bonding characteristics, there is no
mesh reinforcement required for practical application purposes. A fibre
reinforced sprayed concrete layer is recommended as the inner layer.

Water pressure in joints has a very limited influence on the structural design, since
leakage is localised and a composite action of grouted rock mass and composite
lining is created.

Composite lining from external layer

/ MASTERSEAL 345 / internal

Joint water, first drained and later

pushed back by grouting

Figure 2: Application of the MASTERSEAL 345 composite lining in combination with

local joint grouting

At low water pressure the grouting of joints may be avoided. The spots of water
ingress can be sealed off with a fast-setting mortar after the full-face application of
MASTERSEAL 345. These spots can be over coated as necessary with
MASTERSEAL 345 shortly afterwards.
4.2. TUNNEL WITH WATER INGRESS AT ZONES WITH LOCALISED WEAKNESS
For a tunnel with water ingress, but limited to localised zones, it is suggested to
provide permanent drainage and release of water pressure. This can be achieved
through use of pipes, systematic drainage strips, etc.
If the water ingress cannot be limited to local areas, a MASTERSEAL 345
composite lining may not be the most suitable solution and other waterproofing
methods (e.g. sheet membranes) may be considered.
The MASTERSEAL 345 composite lining in combination with appropriate
drainage measures constitutes a system, that is usually called umbrella drainage.

Installation Sequence:
- First apply the sprayed concrete, bolts etc required for support of the rock
mass,
- Then apply the required local or systematic drainage measures. The
drainage pipes or strips should be tightened and smoothly covered with
sprayed concrete.
- Apply MASTERSEAL 345 to the full surface and allow to cure
- Spray the inner lining concrete to a finished profile.
In this case the water pressure is released and thus structurally irrelevant. Loading
of the composite lining comprises self weight (dead load), temperature effects, air
pressure cycling, and potential dead load from the rock mass. It shall also be
considered to have sufficient thickness of the inner sprayed concrete layer to
provide durability against frost at portal zones.

Water proofing layer

MASTERSEAL 345
Water drainage strips or half-pipes

Seeping water

Figure 3: Application case as umbrella system with drainage of limited water seepage
areas. In areas, where frost is not a problem, the thickness of the inner layer of
sprayed concrete may be significantly reduced.

4.3. TUNNEL WITH FULL CIRCUMFERENTIAL WATER PROOFING

The MASTERSEAL 345 composite lining is suitable to construct a water tight
tunnel lining at low overburden (e.g. urban tunnels). This is a variant of the socalled single shell lining. It is important that the ingress of water is limited during
construction of the composite lining, either due to low permeability of the ground,
action of ground improvement measures, or a temporary ground water lowering.
The construction of the MASTERSEAL 345 composite lining in the arch and invert
of the tunnel constitutes a pressure-tight tunnel.
Installation Sequence:
- First the primary sprayed concrete layer with bolts if necessary is applied to
provide the primary ground support.
- Then apply the full circumferential waterproofing using MASTERSEAL 345
sprayable membrane.
- Finally apply the inner sprayed concrete lining. In this case an inner layer
with fibre reinforced sprayed concrete is particularly suitable, saving time
and money. As no mesh reinforcement is necessary, the inner layer could
be very thin.
In the final state the composite lining is loaded by hydrostatic pressure. The
necessary strength and stiffness data for a consideration of the composite action
of primary sprayed concrete, membrane and inner sprayed concrete are given
later in this guideline (see section 6).

Figure 4: Application of the MASTERSEAL composite lining for tunnels with limited
external water pressure.

4.4. SPRAYABLE WATERPROOFING MEMBRANE UNDER COMPRESSION E.G.

FOR CHANNELS, BASINS, WATER TRANSFER TUNNELS
The MASTERSEAL composite lining solution is particularly suitable for watertight
construction of channels, basins or water tunnels with predominantly internal
pressure. In this case the sprayed membrane is under compression. Due to the
bond of the membrane on either side there is no lateral flow of water. Production
of this solution is simple, cost-efficient and ensures high operational reliability.
Installation Sequence:
- Install the primary sprayed concrete layer, typically with mesh reinforcement,
soil nailing, rock support, etc. as required.
- Spray MASTERSEAL 345 during dry weather conditions.
- Apply in the inner sprayed concrete layer, either unreinforced or preferably
fibre reinforced to reduce early crack development.
The loading of the MASTERSEAL composite lining is given as an embedded
structure mainly under compression, and thus is not critical.

Figure 5: Application of the MASTERSEAL composite lining at channels or basins

5.

INSTALLATION
5.1. KEY REQUIREMENTS FOR MASTERSEAL345:
The substrate for the application of MASTERSEAL 345 shall be clean, moistened
and reasonably smooth. A fine-grade sprayed concrete with a maximum grain size
of 4 mm is ideal to achieve this substrate. Substrates with major craters are
unsuitable, or cause excessive material consumption.
MASTERSEAL 345 cannot be applied directly to running water. Running water
spots must be drained or sealed off before the application of MASTERSEAL345.
To achieve full curing, MASTERSEAL 345 requires a minimum temperature of +
5C and a relative humidity of < 90%.
The inner sprayed concrete layer can be applied, when MASTERSEAL 345 has
reached a Shore A strength of at least 25 [2]. This can be expected after 24 hours
at 20C and 65% relative humidity.
5.2. METHOD STATEMENT
Please refer to the separate Method Statement Application of MASTERSEAL
345 Sprayable Membrane, where all practical details and auxiliary measures are
given.
MECHANICAL, CHEMICAL & BIOLOGICAL PROPERTIES

E-Modulus
e-modulus of cured MASTERSEAL 345

Tensile stress/strain of MASTERSEAL

200

345

180

160
140

Fmax [N/mm ]

e-Modulus in MPa

6.

120
100

e-modulus cured MASTERSEAL 345

80
60
40

4
3

cured MASTERSEAL 345 (300d)

2
1

20

10

15

20

25

30

35

40

elongation in %

shear behaviour
please refer to appendix 10.2

bond strength

45

50

20

40

60

80

Elongation %

100

120

140

The Shore A hardness can be used to confirm the bond strength. A Shore A of
25 relates to a bond strength of about 0.5MPa. Fully cured membranes reach
70 80 (Shore A), which is equivalent to about 1 MPa.

7.

crack bridging at thickness of 3mm

MASTERSEAL 345 provides crack bridging capability some hours after
application. Since hardening of the membrane reduces the elasticity, the
minimum crack bridging ability is achieved once fully cured. For a 3mm thick
MASTERSEAL layer this ability is 3mm. For layer thicknesses of 1mm through
8mm, a rule of thumb can be used for evaluation:
Layer thickness = maximum crack width which will be bridged.

Chemical and biological properties

MASTERSEAL 345 is resistant to typical tunnel drainage water.
According to BS 6920 it may also be used in contact with drinking water.

ESTIMATE OF MATERIAL CONSUMPTION AND PERFORMANCE

Installation performance
o Hand spraying:
Time needed for the substrate preparation works depends on the
substrate smoothness and quality encountered.
Typically 50 100m/h may be spray applied by 2-3 operators.
400 800m / shift have been successfully applied.
o Robotic spraying using the MEYCO Robojet Logica [3] application unit:
Time needed for the substrate preparation works depends on the
substrate smoothness and quality encountered.
Up to 180m/h may be spray applied by 2-3 operators.
1500 1800m / shift have been successfully applied.

Material consumption, design thickness

o The design thickness is nominally 3mm.
o For the water insulation a minimum MASTERSEAL 345 layer thickness of
2mm is required.
o 1kg of MASTERSEAL 345 powder is needed per m and mm layer
thickness applied.

Material consumption depending on substrate roughness

o Extremely rough substrate should be covered with a smoothening layer
(sprayed concrete, 2-4mm max aggregate size).
o In spray application on smooth concrete substrates a MASTERSEAL 345
powder consumption of about 3,5kg/m has been achieved.

Spray applications on normal sprayed concrete substrates require 46kg/m MASTERSEAL 345 powder.

Quality control, control of MASTERSEAL 345 layer thickness

o Extremely rough substrate should be covered with a smoothening layer
(sprayed concrete, 2-4mm max aggregate size).
o During spraying regular spot checks with a wet film depth gauge are
recommended.
o Control of consumption rate for a given area indicates average thickness
of MASTERSEAL achieved.
o Thickness control is assured if a MEYCO Robojet Logica spraying
system is used.
o Post application: 5cm x 5cm patches of membrane may be cut from the
surface and checked for thickness. These inspected areas may be quickly
repaired by hand application.
o For determination of curing condition and assessment of mechanical
properties a Shore A gauge may be used to DIN 53505 or ASTM D676. A
guidance table is provided in the Method Statement.

More detailed information is given in the BASF Method Statement Application of

MASTERSEAL 345 Sprayable Membrane.
8.

SUGGESTED BOQ ITEM SPRAYED MEMBRANE:

Detailed information is available as Word document from: www.meyco.basf.com
This document is also available as PDF file.

9.

REFERENCE LIST.
[1]
[2]
[3]

Generic Specification for MASTERSEAL 345, June 2008, Mott McDonald,

BASF Vulkanstrasse 110, 8048 Zrich, Switzerland
Method Statement: Application of MASTERSEAL 345 spray applied
waterproofing membrane, May 2007, BASF UGC International, Vulkanstrasse
110, 8048 Zrich, Switzerland
www.meyco.basf.com

10. APPENDIX

10.1.

Performance properties

Property

Testing Method

Specification

Water vapor diffusion

DIN 52 615

150

Tensile strength at yield

ASTM D638M

From 4 (at + 20C)

Reduce to 0.6 MPa locally
when submerged

DIN 53504 Type S2

300

BS EN 180527-2
Elongation at yield

ASTM D638M
DIN 53504
Type S2

80% - 140% (between -20C

and +20C)

Fire resistant

DIN 4102

B2

Bond to substrate (both

sides)

ASTM D 4541-02

> 0.5

Crack bridging

No norm existent, a
concrete crack in the
composite of concrete
membrane concrete shall
be bridged by the
membrane
Resistant to Sulfates
Resistant to acidic water
Resistant to alkaline water
BS 6920

> 2mm

Rock water resistance

Portable water certificate

10.2.

Graz Report (see separate document)

to be specified according to
local geological conditions
Required when potable
water is in direct contact to
the membrane