Injectable Water-Stop Development

Abraham Bae, Ph.D., P.E.

Korea University
September 21st, 2022
 Table of Contents
1. Motivation

2. Brief Review

3. Design and Manufacturing

4. Injection Process (Working Specification)

5. Performance Verifying Tests

6. 30 M – Real Scale Vertical Injection Test

7. 10 M – Real Scale Vertical Injection Test with Practical Pump

8. Trial Installation and Injection

[Appendix] Patent, Research Paper

1. Motivation
Diaphragm wall was installed for ground support
during main structure construction.
D/Wall D/Wall
For last decade, diaphragm wall was designed
as a part of main structure.
D/Wall D/Wall
Reported Typical Leakages in Diaphragm Wall
in Singapore

D/Wall Joint D/Wall Coupler D/Wall Surface

Primary Cause for Leakage
▪ Insufficient concrete mixture quality due to
1. Narrow Reinforcement Bar Spacings
2. Concrete Casting in (Bentonite + Soil) Liquid
Example of Decent Concrete Quality
▪ Spacing > min. 20 cm → Soil property was quite decent!
▪ Concrete mix quality at the depth of 40 m is secured.
Multi-disciplinary research (RD190004) was
launched to improve waterproofing performance.
▪ Samsung C&T Research Project No. : RD190004

▪ Scope : Focused on Leakage Control at D/Wall Panel Vertical Joint

▪ Objective : Development of “Injectable” Water-Stop

▪ Research Period : 2 years (2018 ~ 2020)

▪ Fund : 236, 000 (SGD)

▪ Multi-Disciplinary Partners:
- Samsung C&T Civil Engineering Dept. (Primary Investigator)
- Daeryong Ind. Co., Ltd. (Manufacturer)

- NSC N106 Project Site (Construction Advisor)

- BASF/SIKA/GRACE (Indirect Participation)

2. Brief Review (Video Clip)
 Video Clip 1
Injectable Water-Stop (DWall Stop)
3. Design and Manufacturing
Conventional water-stop dimension was NOT changed,
and center hole was solely modified as injection tube.
“4 mm of Discharging Slit” was carefully designed by trial-
error tests and numerical estimation.
“Backflow Barrier Seal” was designed for protecting water
infiltration after ground water table recovery.

Benchmarked from BASF

Re-Injectable Tube
4. Injection Process
(Working Specification)
Injection process is composed of 2 steps!
1st Stage: Grouting Material Filling
2nd Stage: Grouting Material Injecting
Identifying grouting material in the 1st stage

Identifying
Grouting Material

1st Stage: Filling

After identifying grouting material, and closing outlet tube.
Injecting work is conducted in the 2nd stage.

Closing Outlet Tube

2nd Stage: Injecting

Grouting material discharges into
any gaps where D/Wall vertical
joint bonding is weak !!
Grouting material is supposed to be discharge in the
direction of main structure!
5. Performance Verifying Tests
Several tests were conducted for verifying
injection performances.

▪ 15 M – Real Scale Vertical Injection Test

▪ Horizontal Injection Test in Casted Concrete Joint

▪ Long-Term Back-Flow Pressure Resistance Test

15 M – Real Scale Vertical Injection Test

▪ Conducted in 15 M building from 3rd Floor.

▪ 4 types of materials were evaluated.

① Water ② Polymer Urethane ③ Micro Cement ④ Modified Acryl

▪ Various injection pressures were applied.

15 M – Real Scale Vertical Injection Test

Injection Chamber at Top Grouting Material Mixing, Viscosity Check

Injection Pressure and Time

Injection Discharging Monitoring
Measurement
15 M – Real Scale Vertical Injection Test
Modified Acryl
Injection Test

Video Clip 2
Polymer Urethane
Injection Test

Video Clip 3
Test Results Summary

Vertical Injection Test

Modified
Type Water Micro Cement PU PU PU
Acryl

Viscosity
1 28 17 300 200 150
(poise)
Material
Temperature
10 21 24 10 18 22
(°C)

Quantity
0.015 0.020 0.015 0.015 0.017 0.012
(m3)

Injection Pressure at Top

2.0 2.0 2.0 7.0 5.0 5.0
(bar)

Pressure at Bottom
1st Filling 3.0 4.0 4.0 3.0 3.0 3.0
(bar)

Time to Fill
21 23 27 300 204 192
(sec)

Injection Pressure at Top

5.0 5.0 5.0 NA 8.0 8.0
(bar)

Pressure at Bottom
3.0 5.0 7.0 NA 4.0 3.0
(bar)
2nd Injection
Time to Injection Completion
65 246 180 NA 322 203
(sec)

Flow Rate
0.340 0.090 0.098 NA 0.144 1.091
(m3/sec)
As material viscosity increases,
time to filling in the 1st stage takes longer.
As material viscosity increases,
the quantity of grouting material in the 2nd stage is reduced.

[ 5 Bar Injection Pressure ] [ 8 Bar Injection Pressure ]

→ Micro Cement, Modified Acryl → Polymer Urethane
Polymer urethane distinguishably exhibits higher
viscosity than micro cement and modified acryl.
Horizontal Injection Test in Casted Concrete Joint

▪ Conducted with concrete mortar casting joints.

▪ 2 types of materials were evaluated.

① Polymer Urethane ② Micro Cement

Horizontal Injection Test in Casted Concrete Joint
Polymer Urethane Injection Test

Video Clip 4
Long-Term Back-Flow Pressure Resistance Test

▪ Conducted in pressurizing chamber.

▪ 5 bar back pressure was applied which represents 50 m below

ground level.

▪ Long-term waterproofing capability was proved for a consecutive

15 months.
Long-Term Back-Flow Pressure Resistance Test
Backflow Resistance Results

Video Clip 5
6. 30 M – Real Scale Vertical Injection
Test (at Sea Water Intake Shaft)
Primary Difference Between 15 m and 30 m Tests

▪ The 15 m test was focused to verify,

- Applicability for various grouting materials → 3 types of materials
- Hydraulic engineering conformance by injection pressure
measurement

▪ The 30 m test was focused to verify,

- Applicability of practical injection pump (or tool)

- Injection performance to the depth where most base slabs belong

in the LTA projects (i.e. 30 m).
30 M – Real Scale Vertical Injection Test Procedure
▪ Project: Gangneung Anin Coal-Fired Power Plant

▪ Location: Intake Shaft (Max Depth: 50 m)

① 3 sets of injectable water-stops were delivered and placed
on the test site with other equipment.
② In order to measure injection pressure,
pressure gage was installed at the bottom of water-stop.
③ The pressure gage was supposed to be recorded by digital camera
which was installed together.

Digital Pressure
Camera Gage
④ The 30-m water-stop was lifted by 25 ton cargo crane.
⑤ Lifted water-stop was laid down inside the shaft.
⑤ Lifted water-stop was laid down inside the shaft.
⑤ Lifted water-stop was laid down inside the shaft.
⑥ Completion of water-stop installation.

30 m
Indication

Pressure
Gage

Digital
Camera
⑦ Inlet tude of water-stop was connected to nozzle of injection.

Connection to Nitrogen Tank Nozzle for Test 1

⑦ Inlet tude of water-stop was connected to nozzle of injection.

Connection to Practical Injection Pump Nozzle for Test 2 & 3

⑧ Grouting material injection

Practical Pump Injection for 30 m

Video Clip 6
Test Factorials

Injection
Injection Tool Material
Pressure

Nitrogen Pressure Chamber

Test 1 Acrylate 4 bar
(Same as 15 m Test)

Practical Injection Pump Low Power → High Power

Test 2 Acrylate
(Electricity-Powered) (Manufacturer’s Spec)

Practical Injection Pump High Power

Test 3 Acrylate
(Electricity-Powered) (Manufacturer’s Spec)
Test 1 Results

Measured Pressure
Time Injection Stage
at the Bottom (Level of -30 m)

0 min 0 sec Application of 4 bar NA

≒
1 min 40 sec Continue NA
Test 2 Results

Injection Measured Pressure

Time
Stage at the Bottom (Level of -30 m)

0 min 0 sec Application of Low-Power 0 bar

~ Continue 1.2 bar

4 min 40 sec Transition to High-Power 1.7 bar

≒
8 min 00 sec 0 bar
Test 2 Observation

At Initial Injection During Injection At Completion

Test 3 Results

Injection Measured Pressure

Time
Stage at the Bottom (Level of -30 m)

0 min 0 sec Application of High-Power 0 bar

0 min 17 sec continued 1.5 bar ~ 1.7 bar

7 min 00 sec continued 0 bar

Test 3 Observation

At Initial Injection During Injection At Completion

Test Summary

Quantity Injection Arrival Time a Duration Measured Pressure

Test No.
of Acrylate Pressure to Bottom of Injection at Bottom

Nitrogen
1 Chamber 27 L 4 bar NA b 100 sec NA b

Pressure

Low-Power Low Power 1.2 bar (at Low Power)

2 56 L 45 sec 480 sec
Injection Pump High Power 1.7 bar (at High Power)

High-Power
3 80 L High Power 17 sec 420 sec 1.5 ~ 1.7 bar
Injection Pump

a Substantially, the ‘time’ means when the bottom is subjected by a certain level of pressure.

It is inferred that the grouting material arrived much earlier than the indicated time.
b In the test 1, the pressure could not be recorded due to misalignment during water-stop laying down.
Discharging Rate (L/sec) as to Injection Capacity
Grouting Material Arrival Time to the Bottom (sec)

NA

※ Note :
In the test 1, the pressure could not be recorded due to misalignment during water-stop laying
down. Arrival time for the “Nitrogen Pressure” test is inferred to be the earliest.
Findings

▪ Practical injection apparatus was found to successfully discharge

grouting material with the developed injectable water-stop.

▪ The experiments proved that the developed injectable water-stop

can be applicable for grouting in structures of which level is at least
G.L. -30 m.
Remarks
▪ In the 30 m tests, the condition of injection slits is ‘opened.’
On the other hand, at field D/Wall joints, most slits would be ‘closed,’
since slits would be embedded and confined along concrete mix.

▪ The loss of injection pressure is expected to be greater in the 30 m tests

than in real D/Wall joint.

▪ Consequently, injection efficiency at D/Wall joint can be improved by

minimizing loss of injection pressure (or energy).

▪ Injected material would be selectively discharged only in the slits

where bonding between D/Wall joint and water-stop is inadequate.
→ Reduction of injection quantity and time
Future Works
▪ Injection performance at actual diaphragm wall joint is necessary to be
examined.
→ Substantial performance is to prevent water leakage at D/Wall joint
after ground water table recovery.

▪ Applicability of Singapore local products (grouting materials, injection

pumps) shall be examined.
7. 10 M – Real Scale Vertical
Injection Test with Practical Pump
Injection Pump Capacity

Mark – II Mark – X
Air Compressor
(Graco Company) (Graco Company)

Continuous Discharging Cycling Discharging Cycling Discharging

Air Compressor Electric Power Electric Power

6 bar Max. ≒ Half of “Mark X” gpm 2.1 gpm

Test
Practical Pump Injection for 2 mm Slit
Video Clip 7
Discharge Rate as to Injection Pump Capacity
8. Trial Installation and Injection
Objectives of Trial Test

▪ Verification of substantial leakage prevention performance of

injectable water stop at D/Wall panel vertical joint

① Identifying leakage stopping by injectable water-stop

② Verifying applicability of injection pumps and grouting materials

in Singapore local market
Section Characteristics
▪ Slip Ramp Road
▪ Semi Top-Down Construction Sequence
▪ 1 m – Thick Diaphragm Wall ERSS
Section Geological Characteristics
▪ Ground Water Table : about G.L. -2 m
▪ Toe Level : G.L. -30 m ~ -40 m
→ Deeper level shall be adopted in ① Min. 5.1 m into G(V) ② at least 25.2 m from FEL.
▪ Final Excavation Level (FEL) : G.L. -6 m ~ -12 m → G(IV)

FEL
Section Water-Stop Design
▪ Water-Stop Design Case for the Lb3 Section Temporary Slab

Roof Slab
→ ‘Condition 2 : No Fissure Grouting’

Base Slab
Final Excavation
Level

Water-Stop
Termination Level

▪ Water-stop shall be installed minimum

up to 10 m depth below FEL without fissure grouting.

▪ Final Excavation Level (FEL) : G.L. -6 m ~ -12 m

▪ Water-Stop Termination Level : G.L. -16 m ~ -22 m

Injectable Water Stop Installation

Injectable Water Stop Installation

Video Clip 8
Trial Injection Test

Trial Injection Test

Dyed Pure Water with Practical Pump (Wagner HP850)
Video Clip 9
Trial Re-Injectable Test

Trial Re-Injectable Test

Acrylate with Manual Pump and Suction Pump
Video Clip 10
Plan for Injection Performance Verification
▪ Overall Plan
- In 2021, water-stop installation, In 2022, injection work at tunnel side excavation

▪ Grouting Time
- When water leakage is
‘observed’ after GWT recovery

▪ Grouting Direction

- Tunnel Side

▪ Leakage controlled can be

visibly verified.
Plan for Injection Performance Verification
1. Water-Stop Installation 2. GWT Recovery 3. Grouting Injection 4. Material Discharging

Pressure-Free Condition Water Pressure by GWT Grouting Material Pressure Discharging

Development Development inside Tube by Excessive Inner Pressure

Ptube= 0 PGWT= 0 Ptube= 0 PGWT= Δ Ptube= Δ PGWT= Δ ΔPtube = ▤

Plan for Injection Performance Verification

By ΔPtube = ▤, the excessive inner pressure inside tube,

The injected grouting material discharges into any gaps

where D/Wall vertical joint bonding is weak !!

Plan for Injection Performance Verification

▪ Duration of injection, grouting quantity, gel time

control, and others will be dependent of users.

▪ For the moistened surfaces, it will be monitored that

① water leakage is stopped by injection works.

② Injected grouting material is pressed out of joints.

Determination of Injection Pressure
▪ Injection pressure will be determined considering the maximum depth of water-stop.

▪ Currently, injection pressure based on standard ground condition will be selected.

Pressure (kg/cm2)
Depth (m)
Standard Bedrock
Monitoring of Injection Mode (P~Q~t Chart)
▪ Typical injection mode will be monitored.

Soil Condition Rock Condition

Selection of Injection Pump
▪ There are customized injection pump types for acrylate and polymer urethane.

▪ Two types of injection pump were recommended by BASF for Singapore grouting works.

※ The most optimized equipment will be selected during this October.

▪ Relatively High Viscosity Material

▪ Polymer Urethane Type Material

▪ Relatively Low Viscosity Material

▪ Acrylate Type Material
Thank You !!
Q&A
[Appendix A] SCIE Journal Publication

Journal of Testing and Evaluation,

Vol. 50, Issue 1, 2022 Jan.
(Currently, On-line Published)