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CI/SfB Yu2 ® Waterproof Concrete Structures Introduction Compelling reasons for using PUDLO David Ball Group plc manufacture cement waterproofing powder products to ensure watertight, reinforced concrete structures. • Quality assured system ® • Proven performance The structures can be water- retaining, such as swimming pools, • Unrivalled track record reservoirs, waste-water treatment • Outstanding customer service and on-site support works and tanks. Or they can be • Expert advice structures that keep water out such as basements, tunnels and • Straightforward and cost-effective waterproofing solution underground car parks. Waterproof • Full warranties and guarantees concrete provides integral protection ensuring that structures are watertight and completely dry. Basement construction using structurally integral protection PUDLO cement PUDLO modified concrete wall. Thickness will determine level of dryness and basement use. waterproofing system 270mm will achieve Grade 4 totally dry environment WALL The system comprises PUDLO cement hDR WATERSTOP fitted to kicker wall and waterproofing powder, an integral between base slab pours. Use INSTAFLEX PU25 MASTIC to adhere to rebate admixture for concrete together with hDR WATERSTOP and INSTAFLEX PU25 PUDLO modified concrete for base slab MASTIC for construction joints. or base slab topping BASE SLAB These faces to be retarded and washed prior to next pour Wall Joint hDR WATERSTOP joint strip into pre-formed rebate • • • Retard these faces and wash down prior to next pour • • Artist’s impression Grosvenor Waterside, London ® PUDLO concrete Typical Results PUDLO cement waterproofing powder is a Control (no admixture) PUDLO concrete BBA approved admixture that can be used to produce watertight, Strength 7 days N/mm 2 33 52 corrosion-resistant Strength 28 days N/mm 2 43 61 structures. Water absorption 28 days % 2.42 1.25 PUDLO is a hydrophobic and pore blocking (BS 1881-122) admixture which alters the microstructure Water Permeability 12.6 < 0.5 of concrete to stop water transport mm penetration mechanisms and increase durability. (DIN 1048-5) By incorporating PUDLO into the Carbonation mm depth 4 <1 concrete mix, it is possible to build Chloride Diffusion 2.05 0.42 watertight structures, without the need m2/s –1 x10 –13 for membranes or drainage systems. PUDLO reduces corrosion mechanisms Microslides showing the reduction in water transport mechanisms due to the addition of PUDLO. within concrete and, as a result, increases White scale denotes voids. structural durability. The system is suitable for use in aggressive and hostile conditions such as coastal defence areas and waste- transfer sites. PUDLO has been used successfully worldwide to provide protection against water ingress and corrosion, even in high exposure class environments. Control concrete PUDLO modified concrete PUDLO performance The modified concrete provides the waterproof, corrosion-resistant solution. PUDLO cement waterproofing powder • Increases the density of concrete by 1% • Improves chloride resistance by 100% • Reduces rate of carbonation by a factor of 4 • Improves surface finish and texture • Increases strengths by a minimum of 10% PUDLO outperforms any other waterproofing admixture. Concrete Specification The concrete mix is the same as normal concrete with the addition of PUDLO at a rate of 2% by weight of cement (this equates to 8kg per 1m 3 of concrete). The concrete should contain a minimum of 350kgm3 of cement and the water/cement ratio should not exceed 0.4. The target slump should be 100mm (+/- 20mm). PUDLO is added at the batching plant with an adequate mixing time of 15 minutes. The material is a non-toxic, odourless, dry powder and packed in 1kg, 2kg, 8kg and 25kg bags. The 8kg bags are soluble and disintegrate in the mix. Screed and Wall Render Specifications Floor screeds and wall renders are made using normal sand / cement mixes. PUDLO is mixed with the dry constituents at a rate of 3% by weight of the cement (this equates to approximately 0.75kg per 25kg cement). Full method statements for screeds and renders are available on request. PROVEN PERFORMANCE ® Our Service and Warranty Technical expertise is provided throughout the project from design stage through to completion. No obligation help and advice is available to the specifier, contractor and concrete supplier. The quality assured User Guide gives comprehensive details on how to correctly use and install PUDLO modified concrete and a technical manager will give on-site support prior to and during pours. David Ball Group plc issue a 30 year company warranty (covering products used and installation) and an independent, insurance-backed guarantee is also available on request. All those involved in the project can be assured that a leak-free structure will be achieved. QUALITY ASSURED Placing PUDLO Concrete SYSTEM The quality assured User Guide gives comprehensive directions for pouring and placing PUDLO modified concrete and a PUDLO representative will carry out in- depth training on site. Particular instruction will be given on compaction and curing, how to form construction joints using hDR WATERSTOP and how to deal with service pipes and tie bolt holes. Case Study 1 Working with Mott MacDonald and Duffy Construction, PUDLO was used in the construction of AIG’s new European headquarters in London. By providing an easy-to-use, membrane- free waterproofing system, contract costs were reduced and one month was knocked off the construction time. The two basement levels had to be completely watertight for document storage and housing electrical equipment. Case Study 2 PUDLO is particularly useful where existing protrusions and features have to be worked around, as in the case of the extensive refurbishment of the Royal Albert Hall. PUDLO modified concrete was employed by Building Design Partnership and John Doyle Specialist Contractor to ensure the waterproofing of the 5 storey underground car park and utilities building. Case Study 3 The Fulham Pools Leisure Centre, designed and built by Amec, contains an 8-lane competition pool, a 6-lane fitness pool and a teaching pool. The concrete mix design for the floor, walls, surface slabs and undercroft of the pool tanks utilised PUDLO waterproofing admixture, hDR WATERSTOP and INSTAFLEX PU25 MASTIC to provide a high performance, water retaining structure. Case Study 4 PUDLO is used extensively on projects around the world. In Dubai, where ground conditions are exceptionally aggressive and saline, the admixture has been used on numerous sites including the Jumeirah Road development. Watertight construction was imperative for this exclusive residential and commercial development. PUDLO modified concrete was used to construct the large basement area designed for car parking facilities. The first membrane-free project in Dubai. ® BS 8102: 1990 – Code of Practice for the protection of structures against water from the ground PUDLO cement waterproofing powder produces Type B structurally integral protection. The grade will be determined by the thickness of the walls and floor slab. Structures can be designed to BS8007 or BS8110. Note 1 Grade Basement Basement Use Waterproof Size The wall sizes are recommendations only – technical Nature Performance mm manager can advise on each project individually 1 Basic utility Car parking; Plant Some seepage 150 Note 2 * Can achieve Grade 4 at 270 (this allows enough rooms (excluding and damp concrete cover to act as a vapour membrane) electrical equipment); patches tolerable workshops Note 3 Grades 3 & 4 need ventilation 2 Better utility Workshops and plant No water 200 rooms requiring drier penetration environment; retail but moisture storage areas vapour tolerable 3 Habitable Ventilated residential Dry environment 250 areas including offices, restaurant, leisure UNRIVALLED centres etc 4 Special Archives and stores Total dry 300 * TRACK RECORD requiring controlled environment environment Underground art gallery – first UK project to use Zero leakage for water testing tanks – national R & D Wimbledon Centre Court Stadium – using lightweight, waterproofed, self-compacting concrete, winning facility for specialist hydraulic and marine environment watertight concrete the loading stresses were reduced Concrete Society Award for Innovation engineers, H. R. Wallingford by 50% at the prestigious sporting venue Front cover: AIG’s new European headquarters in London PUDLO concrete waterproofing products ® PUDLO CWP: dry powder admixture for structural concrete and waterproof renders. hDR WATERSTOP: hydrophilic polyacrylate elastomeric waterstop. Designed for the internal sealing of construction joints for cast-in-place concrete. hDR WATERSTOP expands upon contact with water to form a positive seal even in saline conditions. The waterstop will perform successfully under hydrostatic pressure and under both Waterproof continuous immersion and wet/dry cycling. hDR WATERSTOP is manufactured in 10 metre lightweight, flexible coils of 5mm by 20mm wide dimensions,100metres per box. Concrete INSTALASTIC: liquid-applied, seamless, flexible, waterproof coating which is abrasion- Structures resistant, providing long service-life for extreme service class concrete structures. Supplied in 35kg units (comprising 25kg powder and 10 litres of liquid) one unit is sufficient to apply to an area of 10m 2 with two 1mm coats. INSTAFLEX PU25 MASTIC: high performance, polyurethane single pack, multi-purpose sealant. INSTAFLEX can be used to provide a low skin formation that is fast cure, non- sag and moisture curing. An excellent adhesive for hDR WATERSTOP. PUDLO SCC: extension of PUDLO CWP the admixture is specifically designed to produce high workability, easy to use, self-compacting concrete with the benefits of ultra-low permeability and exceptional surface finish. INSTACEM Primer Latex: blend of acrylic polymer resins that can be used as a primer or sealer. The latex is applied to previously prepared substrate before the application of the cementitious repair material or as final coating. Supplied in 5 litre units, one unit is sufficient to apply to an area of 25m 2 with two coats. INSTAPRUF: cement based, water-resistant, hard wearing, self smoothing floor topping. Supplied in 29kg units (comprising 25kg powder and 4 litres of liquid), one unit is sufficient to apply to an area of 3m2 at 3mm depth. INSTACEM concrete repair: specially formulated, pre-mixed cement powder. The material mixes readily with water to produce a non-shrink, water-resistant, repair material that hardens to give a high strength product. Huntingdon Road Bar Hill Cambridge CB3 8HN United Kingdom Tel + 44 (0) 1954 780687 Fax + 44 (0) 1954 782912 Email [email protected] www.pudlo.com PUDLO is a registered trade name AIG’s new European headquarters in London PRODUCT DATA SHEET PUDLO CWP Durability improver and waterproof powdered admixture DESCRIPTION A hydrophobic, pore-blocking admixture. A dual-purpose, multi-component powdered admixture comprising of a powerful single dosage pack providing outstanding durability and waterproofing properties to all concrete mixes. It also includes plasticising and corrosion-inhibiting benefits. PUDLO outperforms any other admixture of its kind in both durability and impermeability. Where long term durability is critical and / or exposure to aggressive environments is present, PUDLO provides significant key solutions when added to the concrete mix. BBA BBA certificate 01/3843 relates to PUDLO performance characteristics and provides accurate independent data on durability and impermeability. KEY BBA CERTIFICATE FACTORS ASSESSED Durability — concrete containing the product is more durable than the equivalent plain concrete due to its reduced permeability (see section 17 of BBA certificate). Resistance to water penetration — concrete and render containing the product has reduced permeability when compared to the equivalent plain concrete and render (see sections 5 and 6 of BBA certificate). Reinforcement protection — concrete containing the product has enhanced resistance to reinforcement corrosion when compared to the equivalent plain concrete (see section 7 of BBA certificate). Mechanical properties — the mechanical properties of the concrete and render are not adversely affected by the incorporation of the product (see section 8 of BBA certificate). POTABLE WATER APPLICATIONS The product is suitable for use in concrete mixes designed to be in contact with potable water and has been approved by the Water Regulations Advisory Scheme for this purpose. QUALITY CONTROL PUDLO powder is a Quality Controlled, dry powdered product produced in a BS EN ISO 9001 quality manufacturing environment. PUDLO Powder is BBA accredited holding Certificate No 01 / 3843. APPLICATIONS AND BENEFITS  Integral advantages in both high durability and waterproofing environments of all concrete mixes and cementitious based systems  PUDLO is suitable for use with all CEM1 mixes (100% OPC) and cement replacement mix designs using GGBS, PFA and micro silica  To increase durability and minimise permeability, absorption and efflorescence  To provide long-term (building lifetime) durability PRODUCT DATA SHEET  Applicable in all types structural readymix concrete and precast concretes  To reduce shrinkage  Provides permanent significant reduction in permeability  Reduction in carbonation of concrete  Improves resistance to sulphate, chloride and chemical attack including leachates  Enhances protection against frost attack  Provides sound concrete for protection of reinforcement steel  Increases ultimate compressive and tensile strengths without increase in cement content  Reduces bleed and segregation  Reduces efflorescence and staining  Ready to use, readily dispersed, single dose powder, supplied in convenient pre-weighed dissolvable paper bags  Proven world-wide track record with over 130 year history  Concrete mixes containing the product can be placed, compacted and cured by operatives with experience of using conventional concreting methods and equipment  Eliminates the need for any post-applied coating applications or sheet any membrane materials for protection and durability Effects of PUDLO CWP on the hardened properties of concrete Property Control PUDLO Test reference (plain) CWP / concrete Admix 500 concrete Water absorption (%) 28 days 2.42 1.25 BS 1881-122 Water vapour permeability [g.m(N.s)-1] 790 x 10-12 490 x 10-12 BS 1377 Water permeability (ms-1) 3.2 x 10-15 0.64 x 10-15 Taywood/Valenta Drying shrinkage (%) 0.035 0.032 BS 6073-1 Wetting expansion 0.017 0.009 BS 1181-5 Compressive strength 63 82 BS 1881-116 (N.mm-2) 28 days Capillary absorption (g.mm-2 x 10-3) BS EN 480-5(1) 7-day cure 1-day absorption 2.6 0.62 7-day absorption 4.0 0.62 90-day cure 1-day absorption 3.9 1.1 7-day absorption 7.0 1.7 28-day absorption 8.4 2.6 PRODUCT DATA SHEET DOSAGE AND MIXING INSTRUCTIONS The optimum dosage of PUDLO Cement Waterproofing Powder to meet specific requirements should always be determined by trials using materials and conditions that will be experienced in use. As a guide, normal dosages of PUDLO Cement Waterproofing Powder should be in the range 2 – 3% by weight of cement. For example, 1kg PUDLO CWP/50kg of cement. To obtain maximum benefit it is recommended that the water cement ratio should not exceed 0.40. With the correct dosage of PUDLO Cement Waterproofing Powder determined, the required amount should be added to the mix, preferably with or immediately after cement addition. The concrete or mortar produced must be thoroughly mixed until homogeneous. Note: In the event the location of the ready mix concrete supplier (RMC) is within a very close distance to the construction site, the concrete mix containing PUDLO CWP must be given a minimum mixing time of 15-20mins to allow the bag to break up and dissolve. APPLICATION AND USE It is essential that good concreting practice is performed and maintained at every stage of the application process. Concrete modified with PUDLO powder should be placed without segregation, fully compacted and correctly cured in accordance with up to date industry guidelines. Failure to adhere to guidelines and methods of good concrete practice can cause segregation and under compaction and may result in moisture or water ingress. PACKAGING AND SHELF LIFE PUDLO Cement Waterproofing Powder is packaged in 8kg bags or 20kg tubs. Bulk options are available, please contact us for details. The powder has an indefinite shelf life subject to storage in good dry conditions. APPEARANCE PUDLO CWP is an off white/pale grey powder. HEALTH AND SAFETY Use of substance/ preparation: PUDLO CWP (Cement Waterproofing Powder) is a cementitious powder admixture that when incorporated in to concrete or render enhances the water resistance and durability of the hardened product. Company name: David Ball Group Ltd, Wellington Way, Bourn Airfield, Cambridge CB23 2TQ. Tel: 01954 780 687 Fax: 01954 782 912 PRODUCT DATA SHEET HAZARDS IDENTIFICATION Hazard designation: Xi Irritant Information pertaining to particular dangers for man and environment: R 36/37/38 Irritating to respiratory system, eyes and skin. Composition/ information on ingredients: A blend of cementitious powders, aggregates and waterproofing agents. PUDLO Cement Waterproofing Powder is non-toxic and safe to use. However, protective clothing and a dust mask should be worn while mixing the material. Handling: Avoid creating airborne dust wherever possible. Where dust is generated then engineering control measures should be considered (ventilation/ extraction) to maintain the airborne dust concentration as low as is reasonably practical. Storage: Store between +5° C and +35° C protected from frost, sunlight and moisture. Treat as standard Portland cement. Occupational Limits: Total inhalable dust, 10mgm/m³ 8 hour time weighted average. Exposure Standards: Respirable dust, 5mg/m³ 8 hour time weighted average. General protective and hygienic measures: Keep away from foodstuffs, beverages and food. Instantly remove any soiled and impregnated garments. Wash hands during breaks and at the end of the work. Avoid contact with eyes and skin. PERSONAL PROTECTIVE EQUIPMENT (PPE) Breathing equipment: P3 dust mask or similar respirator rated for fine dust. In case of intensive or longer exposure, use breathing apparatus that are independent of circulating air. Protection of hands: Protective gloves. Suitable gloves for the handling of cementitious materials. Eye protection: Eye protection recommended. Body protection: Protective work clothing recommended. The above health and safety information is abbreviated from the PUDLO CWP MSDS/ COSHH data sheet available on request. PUDLO UK is a division of David Ball Group Ltd.