Proiectul hidroelectric Bakun PENETRON PENETRON, PENETRON ADMIX, PENETRON PLUS
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Integral Capillary System Concrete Waterproofing
The Bakun Hydroelectric Project is situated
on the Balui River, Sarawak, Malaysia. The
project is comprised of the construction of a
2,400MW
hydroelectric
dam,
the
transmission of its electricity, and the
building of related infrastructure including
access roads. It is the largest project in
Original Physiognomy of the Bakun HEP
Malaysia, and is known as the “Three
Gorges
Project
in
Southeast
Asia”.
Completion of the project is planned for
2006.
The
powerhouse
of
Bakun
HEP
will
accommodate eight turbine generator units,
giving a total generating capacity of 240MW,
which will meet the increasing demand for
electricity.
This
project
was
first
implemented in the beginning of 1990 but
was shelved in 1997, due to the Asian
Airscape of the Bakun HEP
Economic Crisis, and was resurrected in
2000.
The
Bakun
Project
includes
a
205-high-meter Concrete Face Rockfill Dam
(CFRD) with a crest length of 740 m, a
crest wid
th and base of 12 m and 573 m, a
concrete
open
chute
spillway
of
3
15000m /second capacity, power intakes,
eight power tunnels with a length of 700
Bakun Dam
meters and a diameter of 8.5 meters, power
house, bottom outlets.
-1-
ICS/Penetron International LTD.
The Bakun Hydroelectric Project
Integral Capillary System Concrete Waterproofing
Even high quality concrete is a porous material
--
Excess water evaporation during hardening will leave millions of pores and
capillaries in concrete
Porosity of concrete
--
Allows water to move freely throughout the concrete
--
Increases absorption of harmful chemicals
Moisture and water intrusion
--
Results in chemical corrosion due to the corrosive chemicals dissolved in them
--
Chlorine ion or concrete neutralization (carbonization) can accelerate corrosion
of reinforcing steel
--
Freeze/thaw cycles can lead to concrete cracking and other damage
--
Causes alkali-aggregate reaction
--
Reduces structural property
High sp
eed water current
--
Results in concrete surface abrasion
--
Causes serious cavitations and concrete spalling due to partial low pressure
Over time any untreated concrete structure will slowly succumb to
damage due to the existence of water.
Corrosion of reinforcing steel in concrete
-2-
ICS/Penetron International LTD.
Water & Concrete Deterioration
Integral Capillary System Concrete Waterproofing
There are millions of pores
and capillaries in untreated
concrete.
Water and moisture can
pass through them and
into
the
deleterious
concrete.
The
chemicals
Chlorides penetrate into
dissolved in them will also
concrete with the help of
penetrate into the concrete.
surface moisture and water
The penetration of water
and
harmful
chemicals,
especially chlorides, results
in
the
corrosion
of
reinforcing steel.
Concrete eventually fails
due to further corrosion,
delamination and spalling.
-3-
ICS/Penetron International LTD.
Water & Corrosion of Reinforcing Steel
In
tegral Capillary System Concrete Waterproofing
Solution
concrete, and provide the best protection by providing a great
improvement in pore structure and porosity reduction
--
Penetron
Applied by brush or spray on hardened concrete surface
--
Penetron Plus
Dry shake application on horizontal fresh concrete surface
--
Penetron Admix
An additive mixed into new concrete at the time of batching
for complete integral waterproofing
Penetron products are cementitious capillary crystalline waterproofing
materials
--
Powders consisting of Portland cement, quartz sand and multiple activating
chemicals
Properties
meet
GB18445-2001
the
requirements
“Cementitious
of
China
Capillary
National
Crystalline
Standard
Waterproofing
Materials”
National requirement
testing results
--
Initial setting time
≥20min
199min
--
Final setting time
≤24hrs
5hrs
--
Flexure strength, 7 days
≥2.8
5.8MPa
--
Flexure strength, 28 days
≥3.5
6.3MPa
--
Compressive streng
th, 7days
≥12.0
24.2MPa
--
Compressive strength, 28 days
≥18.0
25.9MPa
--
Adhesion strength, 28 day
≥1.0
1.2MPa
I type
II type
--
Impermeability pressure, 28 days
≥0.8
≥1.2
1.3MPa
--
Second impermeability pressure, 56 days
≥0.6
≥0.8
1.1MPa
--
Permeability pressure ratio, 28 days
≥200
≥300
325%
-4-
ICS/Penetron International LTD.
Penetron products can effectively stop water and moisture penetration into
Integral Capillary System Concrete Waterproofing
ICS/Penetron International LTD.
How Penetron products waterproof and protect concrete
Penetron or Penetron Plus
Typical concrete structure with
When mixed with water and
The
concrete
moisture
applied as a coating, the active
permanently
chemicals in Penetron cause a
neither water nor any other
reaction leading to the formation
liquids are able to penetrate
of non-soluble crystals within the
the
pores and capillary tracts of the
direction
concrete
becomes
sealed
from
a
nd
any
concrete
Concrete was saturated with water so that there is an adequate amount of liquid
water present to allow movement of chemicals into the concrete pores. The
chemicals are pushed into the concrete through the action of diffusion. Under the
right conditions, the chemicals can also move into the concrete by seeping water, or
by the natural wicking action of the concrete.
Once into the concrete, the chemicals react with un-hydrated cement particles and
by-products of cement hydration to form needle-like crystals, which fill and block the
pores and capillaries in the concrete. As water can no longer pass through the
concrete, the concrete becomes “waterproof”.
In absence of moisture, the activating chemicals remain dormant in concrete for
years. If any minute cracks recur, any penetrating moisture will activate the dormant
materials, and the chemical reaction and sealing process repeat itself automatically.
-5-
Integral Capillary System Concrete Waterproofing
Penetro
n
Admix
is
a
ICS/Penetron International LTD.
Penetron Admix
unique
crystal-forming additive that provides
permanent protection for buildings and
other
structures
by
waterproofing
concrete from the inside out.
Penetron Admix is added to the
concrete mix at the time of batching.
The activating chemicals of the product
react with water, unhydrated cement
particles and by-products of cement hydration in concrete to form needle-like crystals.
These crystals grow and migrate through the concrete to fill in hairline cracks and
microscopic voids that would otherwise serve as passages for harmful moisture.
Penetron Admix enhances the natural hydration process in concrete by intensifying
hydration crystal growth, increasing compressive strength and reducing cracking
caused by shrinkage.
In absence of moisture, the activating chemicals remain dormant in concrete for years.
Should cracks recur at any time, these dormant materials are activated by any
penetrating moisture, and the chemica
l action and sealing process repeats itself
automatically.
-6-
Integral Capillary System Concrete Waterproofing
Features, Advantages & Benefits of Penetron Techology
ICS/Penetron International LTD.
Features and Advantages
--
Penetron Admix
Permanent waterproofing admixture
·Impermeability lasts as long as the concrete
·System becomes an integral part of the concrete
·Does not require re-application
Resists high hydrostatic pressure from either positive or negative surface
·Ideal for below grade application
·Does not need any other form of waterproofing
·Protects against water-borne ground contaminants
Protects reinforcing steel from corrosion
·Highly resistant to water-borne aggressive chemicals
·Stops ingress of water required for AAR
·Allows concrete to breathe, eliminating vapor build-up and leaving the concrete
completely dry
Will grow crystals years after initial application
·Will re-activate in the presence of moisture
·Self-heals hairline cracks of up to 0.4mm a
nd stop water ingress that may occur
from subsequent damage to the structure
·Continually improves with time
Multi-functional admixture
·Does not contain stearates, sodium or silicates
·Not a hydrophobic type product
·Not a surface densification product
·Assists concrete in the hydration process, acting as a catalyst to un-hydrated
cement particles already existing in the concrete
·Water-reducing, increasing workability of fresh concrete
·Increases compressive strength of hardened concrete
·Non-toxic, approved for portable water use
-7-
Integral Capillary System Concrete Waterproofing
Penetron or Penetron Plus
In-depth waterproofing property
·Penetrates deeply, and impermeability lasts as long as the concrete
·System becomes an integral part of the concrete, forming a complete body of
strength and durability
·Waterproofing and chemical resistance properties remain intact even if the surface
is damaged
Completely effective against high hydrostatic pressure
·Ideal for belo
w grade application, reservoirs and pipelines
·Does not require protection during backfilling, placement of steel or wire mesh and
other common procedures
·Protects against water-borne ground contaminants
Protects reinforcing steel from corrosion
·Resists chemical attack (PH3-11 constant contact; PH2-12 periodic contact) and
provides a wide range of protection from freeze/thaw cycles, aggressive waters,
sea water, carbonates, chlorides, sulfates and nitrates
·Stops ingress of water required for AAR
·Allows concrete to breathe, eliminating vapor buildup and leaving the concrete
completely dry
Will grow crystals years after initial application
·Will re-activate in the presence of moisture
·Self-heals hairline cracks of up to 0.4mm and stops water ingress that may occur
from subsequent damage to the structure
·Continually improves with time
Efficient and simple application method
·Can be applied from either the positive or negative side
·Can be applied to moist or green concrete
·Can be used for new or existing concrete
·Compatible with water-based glues and surface coatings
-8-
ICS/Penetron International LTD.
--
Integral Capillary System Concrete Waterproofing
High-growth technology
·Zero VOC
ICS/Penetron International LTD.
·Does not contain stearates, sodium or silicates
·Not a hydrophobic type product
·Not a surface densification product
·Non-toxic
·Approved for portable water use
Benefits of Penetron Technology
--
Penetron Admix
Benefits to Property Owners
·Cost effective
·Lowers overall project costs
·Permanent waterproofing system
·Requires no maintenance
·Increases the quality of the concrete for structural performance and integrity
·Increases usage of infrastructure
·Eliminates down-time and costs associated with maintenance and repairs
·Reduces project time requirements
·Long-term manufacturer’s warranty
·Manufacturer’s history of international success in varying climatic & environmental
conditions
Benefits to Contract
ors
·Unmatched technical support
·Reduces application errors associated with installation of other systems
·Improves pouring and placement of concrete
·Eliminates construction delays due to elimination of traditional waiting period to
install membranes on cured concrete
--
Penetron or Penetron Plus
Benefits to Property Owners
·Cost effective
·Lowers overall project costs
-9-
Integral Capillary System Concrete Waterproofing
·Permanent waterproofing system
·Requires no maintenance
·Manufacturer’s history of international success in various climatic & environmental
conditions
Benefits to Contractors
·Unmatched technical support
·Reduces application errors associated with installation of other systems
·Eliminates risk associated with membrane failure
·Requires no protective cement mortar in comparison with other systems
- 10 -
ICS/Penetron International LTD.
·Long-term manufacturer’s warranty
Integral Capillary System Concrete Waterproofing
Comparison of Pene
tron Products to Other
Penetron
Penetron Plus
Penetron Admix
Membranes
(Positive Side)
Other Surface
Applied Products
Cementitious material
Cementitious material added
Liquid and sheet applied
Materials applied to
applied on concrete surface
into fresh concrete to form
bitumens and polymers
concrete surface containing
to transfer needle-like
needle-like crystals within the
affixed to the concrete
mainly water repellents and
crystals to infiltrate the
Description
concrete mass
surface
sealants
·Improves with time
·Improves with time
·Protection breached by
·
Reduces initial absorption
·Resistance to exceeding
·Continuous self-healing
any pinhole or seam
but will deteriorate with
concrete mass
Resistance to
hydrostatic
water
pressure
150m head pressure
·Withstands 3Mpa in
ability
·Initiates full hydration
·Once leaking, will require
replacement
permeability test
time
·Limited penetration leads
to poor resistance to
hydrostatic pressure
Protec
tion of
reinforcing
steel
·Prevents corrosion of
reinforcing steel by
stopping passage of water
· Permanent protection
·
Prevents any permeation of
water and chlorides
and chlorides
·No negative side
protection
·Easily leaks at the joints
and seams
·No negative side
protection
·Limited protection as it
slows the water ingress
in uncracked areas
Crack
self-healing
ability
·Will re-activate in the
·Will re-activate in the
·No self-healing ability
·Can bear excessive
·No crack resistance
presence of moisture to
seal new cracks even
seal new cracks even
years later
Crack
resistance
presence of moisture to
·No self-healing ability
years later
·
Rigid material, can not bear
excessive transformation,
but self heals minor cracks
of up to 0.4mm
·Reduces cracking in plastic
and curing stage
·Self heals minor cracks of
up to 0.4mm in the
transformation
·Limited time protection at
·Temporarily fills existing
cracks
existing cracks locations
presence of mo
isture
Freeze/thaw
durability
· Improves durability by
· Improves durability by
removing water within
removing water within
concrete
concrete
·Eliminates water
penetration at cracks
Repair
requirement
·Slow deteriorating factors
·Permanent waterproofing
protection, does not need
repair
initially
·Slow deteriorating factors
initially
·No durability at crack
locations
·Eliminates water
penetration at cracks
·Easily repaired from
positive or negative side
· Wide range of options are
available
·Repairs are cost effective
·Difficult to repair
·Difficult to locate pinholes
·Repairs may require
removal of previous
materials
and poor joints
·May require total removal
& repair
·
Expensive and sometimes
impossible due to
accessibility
- 11 -
ICS/Penetron International LTD.
Waterproofing Systems
Integral Capillary System Concrete Waterproofing
Penetron
Penetron Plus
Application
Penetron Admix
·
Applied by brush/ spray
·Mixed at batch plant or
side of o
ld/new
concrete
on-site
·No additional
applications required
·Or, dry shake
·Liquids: brush
application
·Sheets: glued or
welded to the
·
Only applied to positive
side
·
Substrate profile critical
to performance
concrete surface
application on
·Correct joints and
horizontal fresh
seams critical to
concrete surface
Surface
preparation
Other Surface
Applied Products
performance
·Needs coarse, water
·No surface preparation
·Clean surface
·Needs surface prep
saturated, clean
·Dry surface
depending on
surface for brush or
·Smooth surface
products requirements
spray
· surface prep for dry
No
shake
Construction
schedule
·Can be applied during
·Added into fresh
·Must be applied at
concrete finishing or
concrete at the time of
completion of
anytime following
batching
structural work
·Saves 10-50% time
·Require protective
and construction
·Some require 28 days
cured concrete
·Similar scheduling as
cement mortar
membranes
costs
Effect
ive land
usage
·Can be applied to the
negative side of
·Can build tight with
property lines
·Spaces required
·Spaces required
between property line
between property line
concrete allowing
and concrete for
and concrete for
construction tight to
membrane installation
surface application
property lines
Sub-surface
drainage
system
Additional
coatings
·Not required
·Not required
·
Require drainage under
·
Require drainage under
high hydrostatic
pressures
·Can be finished with
coatings, tiles, etc.
·Does not affect
coatings
·Adhesion excellent for
high hydrostatic
pressures
·Require protective
·May require special
mortar prior to surface
preparation prior to
finishes
surface finishes
coatings or tiles
Maintenance
·Not only as a surface
coating
·Maintenance not
Service life
required
·Permanent and
improves with time
·Maintenance not
required for the life of
·Costly replacement
generally required
the concrete
·Life time of concrete
·
Re-a
pplication required
under hydrostatic
conditions
·
Become brittle with age
resulting in cracks
and openings
·Surface damage will
·Best when first applied
·Deteriorate with time
·Vulnerable to surface
damage
eliminate protection
- 12 -
ICS/Penetron International LTD.
to positive or negative
Membranes
(Positive Side)
Integral Capillary System Concrete Waterproofing
ICS/Penetron International LTD.
Proposal for Waterproofing of Concrete by Application of
Penetron Products for the Bakun Hydroelectric Project
Proposal for Bakun CFRD
Concrete self-waterproofing treatment + Concrete surface waterproofing treatment
11
Penetron on surface;
Penetron Admix in concrete
10
8
5
4
2
3
6
1
9
7
Waterproofing treatment for CFRD
1 Upstream Blanket Area
2 Repetition Blanket Area 3 Upstream Toe Slab
4 Cushion Layer
5 Transition Zone
7 Downstream Rockfill Area
8 Downstream Slope
10 Concrete Face Slab
6 Main Rockfill Area
11 Upstream Wave Wall
--
9 Downstream Toe of Filter
Zone
Concrete self-waterproofing treatment
Penetron Admix is added into all upstream concrete at the time of batching for
complete integral waterproofing.
--
Concrete surface waterproofing treatment
Penetron is applied on the surface of concrete face slab, toe slab and upstream wave
wall by brush or spray.
- 13 -
Integral Capillary System Concrete Waterproofing
--
Spillway
The spillway is composed of a gated ogee,
an open concrete chute, a flip bucket and
a plunge pool. The ogee, with crest
elevation of 209 meters, is divided into
four 15-meter-wide bays separated by
6.5-meter-wide piers.
The flip bucket and plunge pool are
designed to safely discharge the
floodwater away from the toe of the dam
and the powerhouse. The flip bucket is
designed to be stable under the hydrodynamic forces applied to it by the discharge flows,
and the plunge pool is designed to control the erosive forces of the discharged waters. Its
sides will be protected with a concrete slab anchored in the rock
.
All concrete structures of the spillway contacting with water are recommended:
Concrete self-waterproofing treatment:
--
Penetron Admix is added into the fresh
concrete at the time of batching for complete
integral waterproofing.
Water Conductors
The water conductors include the power
intakes, the pressure shafts and tunnels.
The eight power intakes are joined
together and located in an excavation
next to the spillway, in the left abutment of
the dam. The eight pressure shafts and
tunnels convey the water from the intake
to the turbines in the powerhouse.
All concrete structures of the water conductor contacting with water, or below grade, are
recommended:
Concrete self-waterproofing treatment:
Penetron Admix is added into the fresh
concrete at the time of batching for complete
integral waterproofing.
- 14 -
ICS/Penetron International LTD.
Proposal for other auxiliary structure
Integral Capillary System Concrete Waterproofing
Powerhouse
The powerhouse will be of the surfac
e type,
located on the left bank of the river, near
the toe of the dam but separate from it.
The powerhouse will provide enough
space to install and later operate all the
equipment necessary to generate energy
using an installed capacity of 2,400 MW.
The substructure of the powerhouse will be
founded on sound rock.
Waterproofing of concrete slab of the powerhouse is recommended:
Concrete self-waterproofing treatment:
--
Penetron Admix is added into the fresh
concrete at the time of batching for complete
integral waterproofing.
River Diversion Works
The diversion will consist of upstream and
downstream cofferdams, three river
diversion tunnels and other ancillary
structures.
Three
12-metre
internal
diameter
diversion tunnels, approximately 1400
metres long, will be used to evacuate the
floodwater during construction. The
tunnels will be stabilized using rock bolts
and drain holes as well as through a
process of consolidation grouting and concrete lining. The concrete lining will al
so
contribute to the safety of the tunnels, protecting the rock excavation against erosion due
to the high flow velocities. One of the tunnels will be converted to a bottom outlet after
construction of the project. The outlet structures are designed to protect the tunnels from
retrogressing erosion.
We recommend that Penetron Admix be added to the concrete lining at the time of
batching:
Concrete self-waterproofing treatment:
Penetron Admix is added into the fresh
concrete at the time of batching for complete
integral waterproofing.
- 15 -
ICS/Penetron International LTD.
--
Integral Capillary System Concrete Waterproofing
--
Surface Preparation
The concrete surface must be structurally sound and free of dirt, soil, oil, release
agents, laitance or any other foreign materials which may impair the bond,
penetration and/or overall performance of Penetron materials.
Extremely smooth concrete surface must be water-blasted or sandblasted to make
sure the concrete surface has an open
capillary system.
Rout out visible cracks exceeding 0.4mm in size to a depth of 20mm to 25mm. Also
rout out honeycombed pockets and faulty construction joints to sound concrete.
Construction joints are routed or provided with a formed 20mm*20mm reglet.
Wet down dry surfaces prior to the application of Penetron materials. Moisture must
be present in the concrete strata to ensure maximum chemical penetration. Surfaces
must be damp when Penetron products are applied.
--
Mixing
Brush application: 0.8-1.5kg/m2, 5 parts Penetron to 2 parts water
Spray application: 0.8-1.5kg/m2, 5 parts Penetron to 2.75-to-3.25 parts water (varies
with climate and spray equipment)
Penetron should be mixed to the consistency of thick latex paint. Stir the slurry
mixture frequently during the application and prepare only as much as can be applied
within a 30-minute period.
--
Application
Apply Penetron coating by masonry-type brush (artificial fibers, if available). For
spray application, drop hopper or pis
capillary system.
Rout out visible cracks exceeding 0.4mm in size to a depth of 20mm to 25mm. Also
rout out honeycombed pockets and faulty construction joints to sound concrete.
Construction joints are routed or provided with a formed 20mm*20mm reglet.
Wet down dry surfaces prior to the application of Penetron materials. Moisture must
be present in the concrete strata to ensure maximum chemical penetration. Surfaces
must be damp when Penetron products are applied.
--
Mixing
Brush application: 0.8-1.5kg/m2, 5 parts Penetron to 2 parts water
Spray application: 0.8-1.5kg/m2, 5 parts Penetron to 2.75-to-3.25 parts water (varies
with climate and spray equipment)
Penetron should be mixed to the consistency of thick latex paint. Stir the slurry
mixture frequently during the application and prepare only as much as can be applied
within a 30-minute period.
--
Application
Apply Penetron coating by masonry-type brush (artificial fibers, if available). For
spray application, drop hopper or pis
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