PRE-APPLIED FULLY BONDED HDPE MEMBRANE TECHNOLOGY

FOR CONCRETE PROTECTION

Grace Construction Product

1 INTRODUCTION

In coastal areas, concrete structures are expected to keep out water from the external
environment and withstand severe ground conditions where sulfate and chloride levels,
which are notably deleterious to concrete, far exceed anything found in other areas where
most of the current codes of practice originate. The structures are subjected to extremes of
temperature both seasonal and daily, cycling humidity, and the temperature and humidity
gradient from air-conditioned interior to external ambient.

Exposure conditions of the structural elements during construction must also be taken into
account together with the internal elements of the finished structure which also may be
exposed to the external environment for months during the construction phase. Therefore
the specification of concrete and method of protection needs to be rigorous.

Workmanship is a major factor in obtaining good quality and durable structures and the need
for concreting and membrane installation to be supervised by qualified and experienced
personnel is of prime importance.

Many structures, which are not adequately protected, suffer early deterioration due to water
penetration resulting in corrosion of reinforcement, scaling, cracking and water ingress to the
internal environment.

Figure 1 Pre Applied Fully Bonded HDPE Membrane Installation

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2 DESIGN CONSIDERATION

2.1 Structural Deterioration – Causes

The principle mechanisms of structural deterioration are:

a) Ingress of contaminants.
As a result of evaporation and seawater intrusion, the content of chloride and sulfate may
be higher. This coupled with the high average ambient temperature, gives rise to rapid
build up of chloride at the surface of marine concrete elements, and diffusion through,
often poor quality cover, resulting in early corrosion of reinforcement.

In the region, which often extend several kilometres from the sea, seawater is drawn into
the watertable, and after evaporation, leaves very high concentrations of chloride and
sulfate. These salts can be drawn upward by capillary action and rise many metres into
buildings, with resultant damage to concrete high above ground level. This phenomenon
is often described as ‘wick action’. The conditions are particularly aggressive and wind
blowing over such areas carries salt crystals, which can contaminate unprotected
reinforcement stocks, exposed concrete surfaces and concrete aggregate stockpiles.

b) Cracking, plastic and long term drying shrinkage and thermal cracking.
As noted above the rate of evaporation is high and loss of water from concrete surfaces
can result in early age, plastic shrinkage cracking if proper protection and curing is not
effective. Longer term drying shrinkage will exacerbate the situation and many of these
early cracks widen and deepen.

Plastic settlement cracking is often a concern when increased cover for durability to
reinforcement in columns, results in differential settlement causing cracking in line with
the links.

Concrete temperatures at point of placement should be limited by specification, however

it can be 35°C or above on discharge from the mixer. The heat of hydration liberated over
time as the concrete hardens can result in a temperature rise of 8 to 10°C for every 100
kg of cementitious material in the mix. Where the w/c (water/cement) ratio is fixed at say
0.40, and a cementitious content of 400 kg/m3 is applied, the heart concrete in a large
section can reach 75°C. This temperature in itself causes stresses, which will cause
microcracking, and the gradient between the ‘heartcrete’ and the surface, can give rise to
wide thermal cracks. Cracks, however formed, accelerate the ingress of contaminants to
the concrete core and into the internal environment.

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c) Chloride induced corrosion of reinforcement.
The method of chloride ingress through concrete will be by the processes of sorption and
diffusion. Sorption will occur in highly porous concretes that have a continuous pore
structure. A continuous pore structure is most likely to occur in high water/cement ratio
mixes at or above 0.5, and/or where there is little curing. Curing is essential to properly
hydrate the cement, to create the growth of silicate hydrate, thus segmenting the
capillaries, creating a barrier to the passage of moisture and contaminants.

Most international codes of practice for the design of reinforced concrete structures in
aggressive environments, recommend a w/c ratio of below 0.40.

The high average ambient temperature influences the corrosion mechanism in two ways:

 The rate of diffusion dramatically increases for any quality of concrete, thus shortening
the time to initiation of corrosion, and
 The time between initiation and first visible sign of damage is reduced. A rule of thumb
is that the rate of diffusion, and the rate of corrosion after initiation is doubled for every
10°C rise in average temperature.

Thus it would seem clear from the above that a good specification would minimise the w/c
ratio, use an appropriate cementitious binder, maximise the cover consistent with crack
width control, and ensure full compaction and curing in-situ.

d) Sulfate attack on hardened concrete.

Salts of Magnesium and Calcium Sulfate in solution can react with the hardened cement
paste resulting in expansion and disruption. The sulfates react with the Calcium
Hydroxide and Calcium Aluminate hydrate phases of the binder. The rate of deterioration
of the concrete depends on both the concentration of the sulfate in solution and the
speed with which the sulfate used up in the reaction is replenished.

When assessing the risk of sulfate attack, two main factors should be considered:

 The movement of the groundwater. The ability of fresh sulfate solution to come into
contact with the concrete surfaces and refresh the reaction.
 When a concrete structure is exposed to sulfate conditions on one side, and a dry
environment on the other side, the risk of attack will be greater.

Concrete attacked by sulfate shows a characteristic whitish appearance, with damage

starting at the edges and corners, with progressive cracking and spalling. The concrete
can be reduced to a friable or soft condition.

Increased resistance to sulfate is obtained by the use of cements of low C3A content, by
the inclusion of pozzolanic cement replacement materials such as GGBFS (Ground
Granulated Blast Furnace Slag) or Fly Ash. The most important characteristic of the
concrete itself, is that it must be of low permeability. The free water/cement ratio must be
maintained at 0.40 or less.

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2.2 The Effects of Groundwater

Groundwater surrounding a concrete structure has a significant effect on corrosion providing

both the transport mechanism for harmful salts and as part of the reaction process. The
inclusion of an external tanking membrane on a below ground concrete structure provides
an effective barrier against these mechanisms and prolongs the life of the structure.

Figure 2 Root Causes of Structural Deterioration

2.3 Risk Assessment Considerations for Designing Below Ground Structures

 Internal and external environments

 Cost/risk with regard to construction and maintenance
 Potential risk of changes in surrounding water table levels
 Protection against sulfates, chlorides or other aggressive ground conditions such as soil
and hydrocarbons
 Ground settlement and earthquakes
 Feasibility and form of remedial works should leaks occur

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3 DESIGN SOLUTIONS

3.1 Concrete Design

The design of concrete mixes and careful selection of materials are the prerequisite for
quality concrete. Concrete must be of low water/ cement ratio, typically 0.40 or lower, and
have adequate workability and workability retention to allow placing and full compaction with
the available equipment.

The selection of cement type is important. In recent years the availability of sulfate resisting
(ASTM Type V) has diminished and the practice today is to use a blend of Ordinary Portland
(ASTM Type I) together with a high proportion of Ground Granulated Blast furnace Slag or
Fly ash. The blended cements give the dual benefit of reduced rates of diffusion of chloride
ion, enhanced resistance to sulfate attack together with moderated heat of hydration. The
inclusion of set retarding grades of superplasticisers are essential to secure satisfactory
performance.

The design life of reinforced concrete structures can be significantly extended with the
inclusion of a calcium nitrite based corrosion inhibitor.

3.2 Waterproofing Membranes for Below Ground Structures

Corrosion of reinforcement is the greatest risk to structures. Structures can be designed to

an exposure class with an appropriate concrete specification and cover to reinforcement but
there are numerous situations where such measures will be insufficient for a durable
structure. Indeed, the Guide to the design of concrete structures in the Arabian Peninsular
states that structures expected to perform for more than 30 years or where environmental
conditions are classed as “Extreme” may require additional protection measures (see Table
2 in the Guide).

Such measures should include the protection of below ground structures by the use of
waterproof membranes. Section 3.2.5 Durability provisions - sulfate exposure states “All
concrete below ground must have an effective and durable tanking system.........”.

Section 5.16 Waterproofing/tanking, states “The membrane should restrict the passage of
water between the membrane and the structural concrete. The manufacturer should provide
independent test data to confirm compliance......... It must be durable under the conditions
prevailing and should not permit the passage of chlorides and sulfates to the concrete.”

3.3 A Pre-Applied Fully Bonded HDPE Membrane System Solutions

A pre-applied fully bonded HDPE membranes are impermeable, fully and intimately bonded
membrane barriers and do not suffer the shortcomings associated with loose laid and
compartmentalised PVC membranes.

The membranes effectively protect concrete structures from aggressive contaminants in

groundwater and irrigation water for the life of the structure and in particular:

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 Chlorides and sulfates in solution;
 Oils and hydrocarbons;
 Radon, methane, carbon dioxide, carbon monoxide and other gases;
 Industrial contamination.

Moreover, because it forms a continuous mechanical bond to poured concrete, settlement

between piles will not compromise the waterproofing integrity of the structure as the
membrane still remains adhered to the structural concrete.

Figure 3 Membrane Against Plywood Formwork

High Density Polyethylene (HDPE) sheet is a major component of the membranes. The
functions of the HDPE are to

 provide a portion of the waterproofing protection for the structure and;

 provide increased resistance of the waterproofing adhesive from environmental exposure
and backfill.

HDPE was chosen for this purpose because it has excellent mechanical properties required
for this application including high puncture, tear, and tensile strengths as well as good
elongation for bridging any post-formed cracks in the structure. The other advantage of
HDPE is that it is extremely resistant to attack and degradation from most chemicals.
Consequently, it is typically a leading candidate for use in geomembranes including landfills
containment systems, pond liners, and holding tanks for waste liquids.

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Below grade waterproofing membranes, are often exposed to a variety of soil contaminants
in addition to water. These could include alkalin and acidic environments, petroleum-based
hydrocarbons, and chlorinated hydrocarbons. A number of studies have been conducted on
various materials on the long-term durability of HDPE after exposure to contaminants. The
general conclusion of various studies is that HDPE is one of the more inert materials used in
geomembrane systems. A 1990 publication by the American Society of Testing and
Materials[1] based on an extensive survey of case study testing concluded that the service
life of base polymers, such as HDPE, in flexible membrane liners (FML) used in geotextiles
should last hundreds of years without premature failure. However, the study also stated that
inappropriate applications or installations, such as excessive exposure to UV, heat, and
ozone, could lead to degradation and shorter life expectancy. In summary, HDPE provides
the necessary mechanical properties for waterproofing and excellent chemical resistance
provided the HDPE is protected from excessive exposure to UV, heat, and ozone.

Figure 4 Pre-Applied Membrane Bonded Upwards to Underside of Base Slab

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Picture 5 Pre-Applied Fully Bonded HDPE Membrane is extremely flexible product,
bridges shrinkage cracks in concrete and accommodates minor movement
throughout the service life of the structure with its dimension stability feature.

3.3 Joints in Concrete

A continuous network of impervious waterstops (also known as waterbars) should be

provided in reinforced concrete basements and other below ground structures to ensure
water tightness of movement and construction joints and located to accommodate the
anticipated movement of the structure during and after construction.

There are three types of waterstop in current use:

1. Passive - which provides a permanent physical barrier against ingress of water through
both movement and construction joints. Passive waterstops are typically made of PVC
and are designed for placement either on the external face at the concrete joints or
internally within the thickness of the concrete. Whilst passive PVC waterstops are
suitable for both movement and construction joints, it is becoming more common to
confine passive waterstops to movement joints and ative waterstops to construction
joints. PVC waterstops are available in a variety of shapes and configurations and factory
produced junction pieces can be provided limiting site welding to simple butt joints of
similar sections using an appropriate jointing rig and welding knife.
2. Active - typically preformed strips of hydrophilic material placed midway across the
concrete section of a construction joint prior to placement of the adjacent concrete pour.

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 When fully encapsulated by poured concrete, the expansive forces form a seal against
the concrete face. The seal resists hydrostatic pressure, stopping water from entering the
structure. Active waterstops are acceptable in construction joints and often the preferred
choice because of the simplicity and cost of installation. However, they are not suitable
for movement joints.
3. Combined passive and active - recent advancements have seen the introduction of a
combined system for construction joints. An active outer sleeve of hydrophilic material
surrounds an injection tube. The passive injection tube has an open structure over its full
length, so can be injected to provide an additional line of defense in critical applications.

4 BIBLIOGRAPHY
[1]
Landreth, R. E. and I. D. Peggs (1990), Service Life of Geosynthetics in Hazardous Waste
Management Facilities, in Geosynthetics: Microstructure and Performance (p.26),
ASTMATP 1076, American Society for Testing and Materials, Philadelphia.

British Standards Institution, London

Eurocode 2: Design of Concrete Structures
BS EN 1992-1-1: 2004 General Rules and Rules for Buildings (Formerly: BS 8110)
BS EN 1992-3: 2006 Liquid Retaining and Containment Structures (Formerly: BS 8007)
BS 8102: 2009 Code of Practice for Protection of Structures Against Water from The Ground

Construction Industry Research and Information Association / Concrete Society

CIRIA (1995) Report 139 – Water Resisting Basements
CIRIA (1995) Report 146 – Design and Construction Joints in Concrete Structures
Concrete Society/ CIRIA Joint Publication (2002) Guide to The Construction of Reinforced
Concrete in The Arabian Gulf.
Concrete Society (2008) Guide to The Design of Reinforced Concrete in The Arabian Gulf.

Other Design Guides

IStructE (2004) Design and Construction of Deep Basements Including Cut-and-Cover
Structures.
Institution of Civil Engineers Research & Development Enabling Fund: Reducing the Risk of
Leaking Substructure A Client’s Guide

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