Why Xypex for Tunnels

Meeting the Challenge

Protecting Tunnels

Due to their very nature and location, tunnels can be seriously compromised by hydrostatic pressure and water leakages associated with high water tables. Inadequate waterproofing, cracking and joint failure are problems that will result in the deterioration of concrete and the leaking of water into the tunnel. In the short term, this can lead to the loss of functionality and, over time, compromise the structural integrity of the tunnel itself.

Xypex has an extensive track record in the waterproofing and protection of tunnels. In Cut and Cover, Bored and Immersed Tube tunnels, Xypex is recognized by major contractors as a key solution for the tunneling industry. For cast or pre-cast concrete and shotcrete, Xypex’s non-toxic Crystalline Technology protects tunnels all over the world.Whether used for new construction or the rehabilitation of existing structures, Xypex has gained an exceptional reputation for protecting the structural integrity of concrete and resisting water leakage even under extreme hydrostatic pressure.

Xypex products play a key role in the waterproofing of concrete against water leakage, even against extreme hydrostatic pressure. The unique Xypex technology also protects concrete against the effects of chemical attack and crack or joint failure.

Protecting Tunnels

The waterproofing and protection of concrete in tunnels has the following objectives:

To prevent the passage of water through the concrete due to hydrostatic pressure so as to protect the interior of the substructure from water-damage, and the reinforcing steel from corrosion. Depending on the local environment, concrete may need to be protected against chemical attack from de-icing materials.

The nature of concrete and its installation means having to deal with permeability problems created by the natural porosity of the concrete as well as defects (faulty cold and construction joints, honeycombs, rock pockets and tie holes), joint leaks, freeze/thaw damage and drying shrinkage cracks. These problems typically leave the structure open to active leaks and accelerate the possibility of reinforcing steel corrosion and surface deterioration.

Cracks

Leaking Joints & Tunnels

Construction Defects

Types of Tunnels

Cut & Cover (Bottom-up)

Cut & Cover (Top-down)

Immersed Tube Slide

Drill & Blast

Tunnel Boring Machine

Xypex Crystalline Technology

Xypex products use the natural porosity of concrete and chemical diffusion to penetrate its pores and capillaries. Inside the concrete, Xypex chemicals react with un-hydrated cement particles and the by-products of cement hydration to form a non-soluble crystalline structure deep within the substrate. In this condition, the concrete becomes impermeable, preventing the penetration of liquids and chemicals from any direction even under extreme hydrostatic pressure. The chemical resistant properties of the crystalline structure will mitigate the attack of chlorides or other chemicals that may be present in de-icing materials.

The Xypex Advantage

Xypex Crystalline Technology works inside the concrete, thereby avoiding the problems typical of traditional barrier products.

  • Permanent and reactivates whenever water is present
  • Self-heals static cracks up to 0.5 mm (0.02 in)
  • May be applied on negative or positive side of concrete surface
  • Requires no additional protection as with preformed membranes
  • Resistant to chemical attack
  • Not subject to deterioration problems encountered by surface coatings and membranes

Proven Performance Worldwide

Comprehensive quality systems and standards along with thorough testing in the lab and the field have resulted in Xypex’s highly respected position in the concrete industry. Xypex has been extensively tested by independent testing laboratories in the U.S., Canada, Australia, Japan, Europe and other countries.

Xypex Admix for New Concrete Construction

Xypex Admix is the preferred choice for installing Xypex Crystalline Technology into new concrete tunnel structures. Because Xypex Admix is blended into the mix at the time of batching, it becomes an integral part of the entire concrete matrix, thus reducing the potentially damaging effects of water penetration.

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Xypex Admix Advantages

  • Permanent integral waterproofing
  • Enhances concrete durability
  • Value engineering
  • Non-toxic
  • Non-combustible
  • Resists damaging effects of water penetration and chemical attack

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PRECAST
CAST-IN-PLACE
SHOTCRETE

Rehabilitation & Repair

Xypex’s coating systems and repair products enable transport authorities, engineers and contractors to economically and confidently repair damaged and leaking structures, especially from the negative side. Xypex Concentrate and Modified are applied as slurry coatings to the surface of the concrete. Unlike other materials that need a dry substrate, Xypex products require a moist surface – a condition typical of leaking structures. This type of environment is conducive to the Xypex Crystalline process. Xypex Patch’n Plug, Concentrate Dry-Pac and Megamix products are specifically designed to permanently repair concrete defects such as static cracks and faulty cold or construction joints. These products are also effective at filling tie-holes.

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Xypex Coating Advantages

  • Doesn’t require a dry surface
  • Apply to either side of the concrete
  • Won’t puncture, blister or tear
  • No costly surface priming or leveling
  • Sealing, lapping or finishing is not required
  • No need for protection during backfilling
  • Permanent waterproofing
  • Enhanced concrete durability
  • Doesn’t contain VOCs

Other Accessory Products are also available.
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COATING: Concentrate & Modified
PLUGGING: Patch’n Plug
REHABILITATION: Patch’n Plug & Megamix
Gloria Ferrer Winery – Champagne Caves
Tunnels

Gloria Ferrer Winery – Champagne Caves

USA
Xypex products, Concentrate and Admix, were used to waterproof and protect the retaining walls, slabs, footings, tower walls, tunnels and champagne cellars of this winery. The cellars extend 200 feet underground and provide 4,200 sq. ft. of wine storage. 
Boston CSO Project
Tunnels

Boston CSO Project

USA
Prior to project start-up, CSI installed mechanical mix equipment that allows the concrete mix crews to monitor and quality check the quantity of Xypex Admix added to each pre-cast box. As the concrete cures, Xypex permanently seals the box to prevent the flow of liquids from the outside in, and the inside out. Time of manufacturing to shipping was cut from 30 days to less than 10.
Sydney Airport Tunnel – M5 Motorway
Tunnels

Sydney Airport Tunnel – M5 Motorway

Australia
Xypex was used to meet the concrete waterproofing specifications for the freeway (road) tunnel which runs below the Cooks River beside Sydney’s Mascot Airport. The project involved two contracts – one for 5,000 m3 (Cooks River trough section) and another for 1,200 m3 (Turella Shaft Tunnel).
Okachimachi Tunnel
Tunnels

Okachimachi Tunnel

Japan
Xypex products were used to waterproof various areas of the Okachimachi Tunnel which forms a section (495 metres) of a new artery created for Japan's famous Bullet Trains linking the Tokyo and Ueno Stations. 
Power Plant Szaszhalombatta
Tunnels

Power Plant Szaszhalombatta

Hungary
A two-coat application of Xypex Concentrate was used to waterproof an underground water-carrying channel (200 m long), separated by a concrete wall, from a channel serving as a utility tunnel. After 6 months of operation there were no signs of water leakage into the utility channel.
Bremerton Tunnel
Tunnels

Bremerton Tunnel

USA
The tunnel was to be built on a high water table and its entire length needed waterproofing; shoring of the walls would interfere with any barrier-type system; considerable rebar work was needed on the floor, thus raising the risk of damaging a membrane; and the ceiling would be covered with a 10-ft.-deep backfill making a membrane impractical to repair. Xypex Admix was the answer to all these concerns. 
Aomori Wastewater Treatment Tunnel
Tunnels

Aomori Wastewater Treatment Tunnel

Japan
Xypex Patch'n Plug was used to prevent water leakage from the cracks and construction joints of the original box culvert tunnel. Xypex Concentrate was then applied to the entire surface. To reinforce the ‘box’, a U shaped concrete lining, using Xypex Admix C-2000 was then installed.
Washington D.C. Metro System
Tunnels

Washington D.C. Metro System

USA
Xypex were specified by Bechtel Corp and the Washington Metropolitan Transit Authority for use at various locations of this metro system. Areas of application included tunnel sections, shotcrete vaults, passageways, mechanical rooms, equipment vaults, elevator shafts and various areas in metro stations. The Xypex system was not only used to treat large surface areas but was also used extensively for the repair of severe leakage problems caused by concrete defects and exposure to strong hydrostatic pressures.
Nii Road Tunnel
Tunnels

Nii Road Tunnel

Japan
The concrete of this 30-year-old, 1,290 m tunnel was subject to continuous leakage and freeze-thaw cycles. Repairs, using conventional membrane systems had repeatedly failed. Xypex Crystalline Technology and products were then selected to treat all problem cracks. The application was successful and the leakage was finally stopped.
Ankara Subway Tunnels
Tunnels

Ankara Subway Tunnels

Turkey
Approximately 11,000 linear meters of cracks were repaired with Xypex Patch'n Plug to stop water ingress through the construction joints of this tunnel. A surface area of 5,600 m2 was waterproofed with Xypex Concentrate and Modified.
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