MASTERFLEX 900-FUKO Injection System

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1 MASTERFLEX 900-FUKO Injection System Injection Hose Waterstop System for Construction and Cold Joints in Concrete Function and use The Masterflex 900 hose system is replacing PVC-Waterbars in construction joints. Installed as a preventative measure to test joints against permeability and subsequently inject resin to protect the structure from leakage. The system is used in structures to keep water out, keep water in or both at the same time. When using water based injection resins, re-injection is possible at any time in case of future leakage due to settlement or structural movement at the construction joint. Fields of Application Keeping Water In: Water reservoirs/tanks Canals Dams Sewage treatment plants Liquid storage vessels Any sub base concrete construction Water excluding or retaining structures Keeping Water Out: Basements Parking Garages Underground Stations and Subways Utility Vaults Marine Structures Tunnels Features and Benefits Eliminates costly design, welding and installation of waterbar. Requires no kickers Reduces steps of work to a minimum Water cannot penetrate treated joint to the rebar, unlike traditional installation where water is in contact with the reinforcement up to the waterbar. Fast easy installation procedures even to complicated design detail. Proven and predictable performance. Joints can be tested for water-tightness before backfilling or membrane tanking operations. System enables retro-injection, to stop leaks caused subsequently by settlement or structural movement at the construction joint. The installed system assures a watertight structure. Re-injection is possible at any time

2 Technical Data/Typical Properties MASTERFLEX 900-FUKO injection hose is a specially formulated PVC compound. The material is tough, flexible, resilient, chemically inert, is not affected by weathering, low temperatures, or constant immersion in water. It will withstand rough treatment during installation and is easy to install and splice. MASTERFLEX 900-FUKO injection hose is unaffected by alkalis, sewerage, most water solutions of organic chemicals, aliphatic hydrocarbons (fuel), mineral oils, acids and alcohols. Two basic types of MASTERFLEX 900-FUKO injection hose are available MASTERFLEX 900-FUKO 1: Outside diameter: Longitudinal internal injection hole diameter: Discharge openings diameter: Installation within all types of concrete joints MASTERFLEX 900-FUKO 2: Outside diameter: Longitudinal internal injection hole diameter: Discharge openings diameter: Installation within concrete joints, tunnels or voids where large quantities of injection materials are to be injected. 19mm 6mm 3mm 24mm 10mm 5mm Installation Procedure Preparation All MASTERFLEX 900-FUKO injection hoses should be protected from oil, dirt, concrete spatter and damage and should be left clean to receive concrete. Method Keeping Water In: The MASTERFLEX 900-FUKO injection system consists of the injection hose itself and the vent ends. These are specially fabricated PVC hoses to withstand injection pressure, in green and transparent colours. The vent ends allow the injection at a later stage and are approximately 40 cm long, or as required by the structure. After pouring the concrete, only the vent ends are visible. The different colours are made to localise the hose easier at concreting. The injection hose must be encased in at least 5 cm of concrete and vent ends should be kept inside the concrete for 15cm. The MASTERFLEX 900-FUKO injection hose is installed in lengths up to a maximum length of 12m. For normal wall thickness the MASTERFLEX 900-FUKO hose has to be installed in the centre of the installation. The hose is clamped into position with MASTERFLEX 900-FUKO clips spaced about 250mm apart. The hose must not be fastened to the reinforcement bars in the wall. It is essential that there is a direct contact between the hose and the concrete. If aggregate or debris lie on the concrete, these must be removed, to prevent floating of the hose in the freshly poured concrete. The surface where the MASTERFLEX 900-FUKO injection hose will be installed has to be smooth. The surface generated by an internal vibrator while compacting the concrete will usually be suitable.

3 Guidelines Installation, injection, re-injection, and selection of materials should be entrusted to an experienced and certified MASTERFLEX 900-FUKO applicator. The period between pouring and injecting is determined by the curing time of the concrete. The usual minimum period is 28 days. If this is not possible please contact BASF Construction Chemicals (UK) technical services department. MASTERFLEX 900-FUKO 1 injection materials: a) MASTERFLEX 601 b) RHEOCEM microcements Injection of the MASTERFLEX 900-FUKO hose with MASTERFLEX 601 or Rheocem permits re-injection: As from the moment that no material flows into the joint and there is no (or only slight) pressure drop at the gauge; maintain the pressure for approximately 5 minutes at 40 bar. This is essential to allow the injection material to penetrate into the joint. Sealing is achieved by moderate pressure and a longer injection time, as opposed to high pressure over a brief injection period. Adopt the same procedure from the other end of the MASTERFLEX 900-FUKO hose, this is to ensure even pressure distribution over the whole length. During the gel time, pressurise the hose again briefly. If material penetrates the joint and appears at the wall surface. The joint surface should be patched with rapid setting cement; Thoro Waterplug Components of the MASTERFLEX 900-FUKO HOSE MASTERFLEX 900-FUKO 2 injection materials: a) OPC with RHEOBUILD b) RHEOMAC GF320 c) MASTERFLEX 601 d) RHEOCEM microcements Injection always starts at one end adopting the following procedure: Fill the hose with injection material by means of an injection pump until it flows out at the other end. Plug that end with a special packer. Pressurise the MASTERFLEX 900-FUKO hose to between bar. 1. Injection diameter, 6 or 10 mm, depending on the injection material. 2. Solid hose core for absorbing the concrete pressure. 3. The lateral openings with a diameter of 3 or 5mm, each staggered by 1cm, ensure a uniform discharge of the injection material. 4. The four neoprene strips in the longitudinal grooves act as non-return valves.

4 Method Keeping Water Out: MASTERFLEX 900 FUKO HOSE SYSTEM is used with MASTERFLEX 801 an injection and filling resin for the injection of damp and humid cracks through packers and injection hoses in concrete and stone. The MASTERFLEX 900 FUKO HOSE SYSTEM is easy to install and maintain. It consists of: Junction Box Masterflex 900 Hose Tape Nozzles Rapid Glue Sleeve Heat Gun The step by step installation is as follows: Secure section of hose with tape before cutting Cut to desired length Vertically cut at a 90 0 angle Insert nozzle Secure with rapid glue Place shrink sleeve over MASTERFLEX 900 Secure vent hose with rapid glue Position shrink sleeve in centre Heat shrink sleeve for tight fit Connect to junction box Flush with MASTERFLEX 801 resin Secure junction box For full installation details please see our installation guidelines or contact BASF Construction Chemicals (UK) technical services department.

5 MASTERFLEX 900-FUKO BASF Construction Chemicals UK Ltd Version 4, July 2006 Health and Safety *For full information on Health and Safety matters regarding this product the relevant Health and Safety Data Sheet should be consulted. The follow ing general comments apply to all products. As with all chemical products, care should be taken during use and storage to avoid contact with eyes, mouth, skin and foodstuffs, (which may also be tainted with vapour until the product is fully cured and dried). Treat splashes to eyes and skin immediately. If accidentally ingested, seek medical attention. Keep away from children and animals. Reseal containers after use. Solvent Based Products Use in well-ventilated areas; avoid inhaling. Suitable respiratory equipment may be needed, eg when spraying. Can cause skin, eye irritation. Wear protective eye shields and gloves during use. Do not smoke or allow sparks or naked lights when stored or in use. Powder Products Should be handled to minimise dust formation; use light mask if excessive dust unavoidable. Cement powders when wet or moistened can cause burns to skin and eyes which should be protected during use. Resin Products Can cause irritation, dermatitis or allergic reaction. Use protective equipment particularly for skin and eyes. Use only in well ventilated areas. Spillage Chemical products can cause damage; clean spillage immediately. Disclaimer: This information and all further technical advice is based on our present knowledge and experience. However, it implies no liability or other legal responsibility on our part, including with regard to existing third party intellectual property rights, especially patent rights. In particular, no warranty, whether express or implied, or guarantee of product properties in the legal sense is intended or implied. We reserve the right to make any changes according to technological progress or further developments. The customer is not released from the obligation to conduct careful inspection and testing of incoming goods. Performance of the product described herein should be verified by testing, which should be carried out only by qualified experts in the sole responsibility of a customer. Reference to trade names used by other companies is neither a recommendation, nor does it imply that similar products could not be used.