Injection

Solutions for Underground Construction

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Master Builders Solutions

from BASF

The Master Builders Solutions brand brings all of BASF’s

expertise together to create chemical solutions for new
construction, maintenance, repair and renovation of structures.
Master Builders Solutions is built on the experience gained
from more than a century in the construction industry.

The know-how and experience of a global community

of BASF construction experts form the core of
Master Builders Solutions. We combine the right elements
from our portfolio to solve your specific construction
challenges. We collaborate across areas of expertise and
regions and draw on the experience gained from countless
construction projects worldwide. We leverage global BASF
technologies, as well as our in-depth knowledge of local
building needs, to develop innovations that help make you
more successful and drive sustainable construction.

The comprehensive portfolio under the

Master Builders Solutions brand encompasses concrete
admixtures, cement additives, solutions for underground
construction, waterproofing solutions, sealants, concrete
repair & protection solutions, performance grouts,
performance flooring solutions.

Global Underground Construction Team

BASF, with its global underground construction team,
is a world leader in the provision of reliable,
customer-oriented solutions focused on your needs in the
tunneling and mining industries. We recognize that your
success is underpinned by our ability to deliver solutions
that meet or exceed your critical needs.
By accompanying you from the start of your project and
understanding the issues that are important to you, we can
contribute to your success. We support you with product
training and quality control, and our professional technical
services team is on hand around the clock, helping you
with specialist technical advice and trouble shooting.
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Avoid the Unexpected with Pre-Injection Ground Consolidation

Unexpected water ingress and poor ground Fast-reacting and non-water-sensitive polyurea
conditions during underground construction silicate systems quickly stabilize poor ground.
usually escalate costs, can have a negative The high-foaming version is excellent for void
influence on the environment, and inevitably filling. The less water-sensitive polyurethanes
cause significant delays. To counteract these are also suitable to strengthen the ground.
risks, an economical approach is to pre-inject
the ground ahead of the advancing face to Crack Sealing and Concrete Rehabilitation
avoid water ingress occurring, and to stabilize The range of acrylic resins are particularly
the ground. suitable for rehabilitation injection for cast
Microcements and colloidal silica, the concrete, segment linings and brick & masonry
latter also known as mineral grout, allow lined tunnels.
a cost-effective approach and improve
working safety with minimal environmental
consequences.

Water Stopping
Foaming, water-sensitive polyurethanes are
ideally suited to combat water ingress quickly
and effectively. For particularly difficult cases
the solution is a combination of drainage and
the injection of a fast-reacting foaming resin.
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Microcement

Excavation face

Injection drillhole
Tunnel invert Injection
lance

Stable microcement penetrating fine fissures

Fast Setting, Fast Cycle

MasterRoc MP microcements (formerly RHEOCEM®)
are a range of superfine portland cements for pre-
injection application. Due to their fineness they provide
extremely effective penetration into fine cracks in rock
and fine grained soils to give efficient water tightness,
stability and durability.
They represent a significant technological advantage in
cementitious injection. Their unique and innovative feature
is rapid and controlled setting, allowing uninterrupted
blasting rounds or continued injection sequences, thereby
enhancing productivity considerably.
Where it would take 6 hours between blasting rounds with
normal cement, the waiting time is only 2 hours with
BASF’s microcements.

Stable (left) vs. unstable (right) grout

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Fine fissure
0.02 mm
Colloidal Silica, MasterRoc MasterRoc MasterRoc Ordinary Portland Cement
MasterRoc MP 320 MP 900 MP 800 MP 650 CEM I 52.5
0.015 µm 9 µm 12 µm 15 µm 40 µm

Illustration of the difference in D95 values of MasterRoc MP microcements compared to ordinary Portland Cement

Microcement - Stable Penetrating Grout Limit Grout Travel Distance with

A stable grout is crucial for efficient penetration Accelerated Setting of Microcement
into the rock, and cannot be achieved with The setting of microcement grout suspensions
ordinary cement. A stable grout can travel far can be accelerated with a controlled dosage
without losing its effectiveness, reducing time of a specially designed alkali-free accelerator.
required for a given result as less drilling and Using this unique method, the open time of the
less pumping are necessary. Microcements grout suspension can be controlled from 1-2
penetrate small cracks and inter-granular minutes up to approximately 20 minutes,
spaces very well, and allow high pumping remaining pumpable before it sets and becomes
pressure where needed as the grout remains solid.
stable. A further benefit is that standard cement This is particularly suitable for situations where
injection equipment can be used. controlled injection is needed to limit grout
spread in very permeable rock masses and
soils, as well as for cold groundwater
conditions where very fast setting is necessary.

MasterRoc MP microcements are available on

special request as slower setting sulphate
resisting versions and in different grades
relating to the maximum particle size as given
by the D95 values illustrated in the image above.
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Polyurethane and
Polyurea Silicates

Water Stopping, Water Sealing,

Consolidation and Cavity Filling
The MasterRoc MP 350 series of polyurethanes Many of the products for preventing water
and the fire-resistant (according to DIN4102-B2) ingress can be adjusted on site to give varying
MasterRoc MP 360 series of polyurea silicates performance properties to suit the conditions
are designed for water stopping and sealing, using different accelerators. All MasterRoc MP
strata consolidation and cavity filling polyurethane and polyurea silicate products are
applications, meeting the modern-day demands solvent free, and all foaming products build
of the tunneling and mining industry. The range closed-cell foams, acting as a water barrier.
varies from a convenient 1-component PU for They have been tested and certified by external
small water sealing jobs to specialist robust institutes in terms of technical properties and
2-component systems to effectively stop health and safety aspects.
massive water ingress problems.
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Ground consolidation with MasterRoc MP 364 Flex Cavity filling with MasterRoc MP 367 Foam

Water Stopping Ground Consolidation

MasterRoc MP 355 1K MasterRoc MP 358 GS / MP 358 SC

 To stop low- to mid-volume water ingress  To consolidate fractured ground,
 Reaction time: 10 to 120 seconds at 20°C low sensitivity to water
(accelerator provided to adjust reaction time)  Reaction time: 30 to 70 seconds
 Foam factor: 20 to 30  Foam factor: GS – up to 1.5, SC – up to 3
 MasterRoc MP 355 1K DW is an almost  2-component pump
identical product with a potable water
approval
 1-component pump MasterRoc MP 364 Flex
 Dense glue-like resin for fractured rock,
gravel and coal, not sensitive to water
MasterRoc MP 355  Reaction time: 90 to 120 seconds
 To stop mid- to high-volume water ingress  Foam factor: 1
 Reaction time: 20 to 70 seconds depending  2-component pump
on accelerator type
 Foam factor: 8 to 20 depending on accelerator
type MasterRoc MP 367 Foam
 MasterRoc MP 355 Thix is a similar product  Brittle foam for cavity filling in rock,
for very high-volume water ingress gravel and coal, not sensitive to water
 2-component pump  Reaction time: 10 to 60 seconds
 Foam factor: 2 to 30
Water Sealing  2-component pump

MasterRoc MP 350
 For permanent structural crack sealing of
concrete and masonry structures
 Reaction time: 30 to 100 seconds
 Foam factor: up to 8
 1-component pump
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Acrylic Resins

Crack injection in tunnel linings

Possibly leaking joints

Goal of injection:
to section and create barriers,
subsequently removing water.

Water can flow in every direction,

before and during injection.

Strong Durable Gels for Crack Sealing Certification

and Concrete Rehabilitation The European CE certificate specifies
The MasterRoc MP acrylic series is a range of requirements and conformity criteria for the
high-performance acrylic resins that identification, performance (including durability
permanently seal the finest cracks in concrete aspects) and safety of injection products for the
instantly and even accommodate limited repair and protection of concrete structures.
movement due to their flexibility and swelling
capability. They are also ideal products for Two of our latest acrylics, MasterRoc MP 303
curtain injection behind leaking tunnel linings CE and MP 307 CE have CE certification for
and diaphragm walls. the “swelling fitted filling of cracks, voids and
Furthermore, they can stabilize weak soil and interstices in concrete” according to EN 1504-5.
sand immediately and seal off water. They are
widely used in major infrastructure projects
such as power stations’ generator housings for
the permanent waterproofing of concrete
defects.
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Mastering underground construction challenges requires the right partner.

Continuous innovation and customized solutions ensure that customers
using Master Builders Solutions operate successfully, and to the highest
safety standards.

Crack Sealing and Rehabilitation Ground Consolidation

MasterRoc MP 303 CE MasterRoc MP 309

 Flexible with good adhesion to wet rock  Extremely strong with good adhesion to wet
and concrete and can swell up to 200% rock and concrete, for consolidation in silty
 Reaction time: 10 seconds to 3 minutes and sandy strata
 Viscosity: 5 mPa·s  Reaction time: 45 seconds to 8.5 minutes
 2-component pump  Viscosity: 13 mPa·s
 2-component pump

MasterRoc MP 307 CE
 Rubber-like and very flexible with good adhesion
to wet rock and concrete, balances ground
movement, for “living cracks”
 Reaction time: 4 to 17 minutes
 Viscosity: 7 mPa·s
 1- or 2-component pump
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Colloidal Silica

The Mineral Grout

MasterRoc MP 320 and MP 325 are colloidal Having a viscosity similar to water, colloidal
silica gels, referred to as “mineral grouts”. silica penetrates soils and fine rock fissures
These are not chemical grouts and consist very easily, ensuring unrivalled penetration and
only of natural ingredients (quartz sand, water permanent stabilization of fine, silty sands.
and salt). They are made of a stable liquid Unlike sodium-silicate-based products
dispersion of discrete, nanometric spherical (waterglass), colloidal silica is durable and does
particles composed of 100% amorphous not affect the pH value of the ground water, and
silicon dioxide. The colloidal silica products continually gains strength over time. The gel
are used in jointed rock and fine grained time can be adjusted to between 10 minutes
soils mostly as a supplement to microcement and 2 hours, allowing for adaptation to the
injections to achieve the final required result needs of each project. A further benefit is that
and where durable long-term solutions for standard cement injection equipment can be
water sealing and ground stabilization are used.
required.
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Training and Education experienced instructors. The main objective is

BASF provides technical injection training to gain practical skills for the correct application
courses on a frequent basis centrally located in and execution of injection works.
the Hagerbach underground facility in In addition, tailored training is organized for
Switzerland. The courses are organized both as individual projects worldwide when required by
demonstration workshops in realistic customers.
underground settings and as practical injection
operators’ training.
The demonstration workshops are practical Technical Services
“show-and-tell” sessions and aim to visualize BASF provides more than simply a range of
and explain the possible types of application products. Assisting customers in selecting the
and the technical performance of our injection right injection system and setting out the
systems. injection method, as well as providing initial
The practical injection operators’ training is supervision and site training of the customer’s
offered exclusively to injection customers who personnel, is an essential part of our concept.
are working with BASF injection systems. BASF works together with suppliers of
During this training the participants are given equipment and injection accessories to provide
the chance to work in small groups, taking part the best, most cost-effective and complete
in hands-on exercises under the supervision of technology solution.

More brochures on our underground construction solutions are available at www.ugc.basf.com

Documentation available on request:

 Reference list
 Project reports
 Technical data sheets
 Design guidelines
 Method statements
Master Builders Solutions from
BASF for the Construction Industry
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air-entrained concrete fiber-reonforced concrete concrete
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Solutions for concrete strengthening Solution for hyperplasticized concrete Solutions for water-reduced concrete
MasterTop
MasterCast MasterInject MasterProtect Solutions for industrial and
Solutions for the manufactured Solutions for concrete injection Solutions for concrete protection commercial floors
concrete product industry
MasterKure MasterRheobuild Master X-Seed
MasterCem Solutions for concrete curing Solutions for superplasticized Advanced accelerator solutions for
Solutions for cement manufacture concrete pre-cast concrete
MasterLife
MasterEmaco Solutions for enhanced durability MasterSeal Ucrete
Solutions for concrete repair Solutions for waterproofing Flooring solutions for harsh
MasterMatrix and sealing environments
MasterFinish Advanced rheology control solutions
Solutions for formwork treatment for self-consolidating concrete MasterRoc
Solutions for underground
MasterFlow MasterPel construction
Solutions for precision grouting Solutions for watertight concrete

Headquarters
® = registered trademark of BASF group in many countries

BASF SE BASF Construction Chemicals BASF Australia Ltd

Underground Construction 23700 Chagrin Boulevard 11 Stanton Road
Salzachstrasse 2-12 Beachwood, OH 44122, USA Seven Hills NSW 2147, Australia
68199 Mannheim, Germany Phone +1-216-839 7500 Phone +61 2 8811 4200
Phone +49 621 60 91013 Fax +1-216-839 8821 Fax +61 2 8811 3299
E-mail ugc@basf.com E-mail admixtures@basf.com

BASF Construction Chemicals UAE LLC BASF SA BASF Construction Chemicals Asia Pacific
P.O. Box 37127 Avenida das Nações Unidas, 33 Tuas Avenue 11
Dubai Investment Park 14.171, Morumbi Singapore 639090
UGC®: 09/13/Jellyfishadv

Al Hibab Road, Jebel Ali 04794-000 São Paulo – SP, Brazil Phone +65 6861 6766
Dubai, United Arab Emirates Phone +55 11 2718 5507 E-mail infotmc-ap@basf.com
Phone +971 4 8090800 E-mail sac.eb@basf.com

The data contained in this publication are based on our current knowledge and experience. They do not constitute the agreed contractual quality of the product and, in view of the many factors that
may affect processing and application of our products, do not relieve processors from the responsibility of carrying out their own investigations and tests. The agreed contractual quality of the product
at the time of transfer of risk is based solely on the data in the specification data sheet. Any descriptions, drawings, photographs, data, proportions, weights, etc. given in this publication may change
without prior information. It is the responsibility of the recipient of our product to ensure that any proprietary rights and existing laws and legislation are observed (08/2013).