WATERPROOFINGREPORT

ON SITE | PAGE 5

RESEARCH & DEVELOPMENT | PAGES 6– 7

Waterproofi ng Systems

TITLE ARTICLE | PAGES 2– 4

Waterproofi ng in the metro system of Athens

Subsequent installation of horizontal barriers

Fast systems for waterproofi ng from the inside

EditorialKÖSTER NB I “Fast”

Fast waterproofing systems forwaterproofing from the inside

E D I T O R I A L

Fast waterproofing system 1: Pressurized waterKD 1 KD 2 KD 3 KD 1

The factor time is and will remain thenumber one cost driver in the construc-tion industry. On the on hand, cus-tomers alwaysdemand increasingperformance fromcraftsmen and on theother hand, cus-tomers alwaysincrease pressure onthe prices of crafts-men. KÖSTER BAU-CHEMIE AG stands upto this challenge together with its cus-tomers by bringing product systems tothe market which allow cost-efficientand reliable-design waterproofing.

Already, the classic – the KÖSTER Crisin®76 suction angle injection systemagainst rising damp – stands outbecause of its time-saving processing. Ithas also proven itself in the laboratoryand in the field even in cases of highlevels of moisture penetration.

The user-friendliness of the system incombination with the high level of cer-tainty regarding the effectiveness of thesystem were the reasons for the devel-opment of the now already well provensystem around the central productKÖSTER Restoration Plaster 2 “Fast”.

We now introduce you to the newestproduct of our program for fast and safewaterproofing, the product KÖSTER NB 1“Fast” which closes the gap between ourKÖSTER NB 1 Grey and the KÖSTER KD-system. This product unites the very fastcuring of the KÖSTER KD-system withthe very simple application of theKÖSTER NB 1 Grey / KÖSTER Polysil® TG500 system.

You will find more about that in thisedition of the Waterproofing Report, inwhich we would like to demonstrate toyou the innovative power of the KÖSTERBAUCHEMIE AG by way of example.

With best regards from Aurich

Dr. Uwe WirringaHead of Research and Development

With the new waterproofing prod-uct KÖSTER NB 1 “Fast”, KÖSTERBAUCHEMIE accommodates thewide-spread time pressure in theconstruction industry by uniting

the technical advantages of thewell proven KÖSTER KD-Systemwith the positive processingproperties of KÖSTER NB 1 Grey.

08.00 a.m. 08.30 a.m. 09.30 a.m. 09.4

Fast waterproofing system 2: Non-pressurized waterPolysil® 1. Layer NB 1 “Fast” 2. Layer NB 1 “Fast” Harde

Polysi

08.00 a.m. 08.15 a.m. 09.00 a.m. 09.30

Fast waterproofing system 3: Damp wallsPolysil® TG 500 Plaster key Restoration plaster Smoot

08.00 a.m. 08.15 a.m. 09.15 a.m. 10.15

This new fast waterproofing sys-tem is the first choice for water-proofing against non-pressurizedwater and thereby closes the gap between fast waterproofingagainst pressurized water (nega-tive side waterproofing againstleakages with the KD-system) and plain plastering of moist wallswith a combination of KÖSTERPolysil® TG 500 and KÖSTER

Restoration Plaster 2 “Fast”.KÖSTER NB 1 “Fast” is a fast-set-ting, rigid mineral sealing slurryfor positive and negative sidewaterproofing in new buildingand restoration. After the producthas been mixed with water, it setswithin approximately 15–30 min-utes under minimal heat develop-ment and can already bear lightloads after 2–3 hours. KÖSTER NB 1

“Fast” is principally always com-bined with KÖSTER Polysil® TG500. On one hand, the substrateto be sealed is solidified throughthe application of the KÖSTERPolysil® TG 500 and a uniformabsorbency of the substrate isproduced. On the other hand,KÖSTER Polysil® TG 500 is appliedon top of the second coat ofKÖSTER NB 1 “Fast” to harden the

KD 1 Plaster key Restoration plaster Smoothing

45 a.m. 10.15 a.m. 11.00 a.m. 12.00 a.m. 13.00 p.m. 13.30 p.m. – finished

ening with Plaster key Restoration plaster Smoothingl® TG 500

0 a.m. 10.00 a.m. 11.00 a.m. 12.00 a.m. 12.30 p.m. – finished

thing

a.m. 10.45 a.m. – finished

KÖSTER WaterproofingReport | 2/3

TITLE ARTICLE

slurry. Hardening with KÖSTERPolysil® TG 500 between the twocoats, as required in the case ofnegative side waterproofing withKÖSTER NB 1 Grey, is not necessary.

KÖSTER NB 1 “Fast” bonds to thesubstrate as homogenously asKÖSTER NB 1 Grey does and itenters a monolithic bond withthe substrate.

Start in the morning,be finished by noon.

Principally, the applicationsequence of KÖSTER Polysil® TG500 and KÖSTER NB 1 “Fast” isdone fresh in fresh, waiting timeis only approx. 15 minutesbetween the priming of the sub-strate with KÖSTER Polysil® TG500 and the application of the

first coat of sealing slurry.After the slurry has been hard-ened with KÖSTER Polysil® TG 500,a further waiting time of 15 min-utes must be observed until plas-tering can be started with theapplication of a plaster key madeof KÖSTER Restoration Plaster 2“Fast” and KÖSTER SB-BondingEmulsion “Concentrate”. After avery short curing time (30–60minutes), plastering can be carriedout in one layer using KÖSTERRestoration Plaster 2 “Fast”.Due to the extremely short curingtimes of both, the waterproofingmade from KÖSTER NB 1 “Fast”and KÖSTER Restoration Plaster 2“Fast”, restorations of small areascan be carried out within one day.Waiting times between the indi-vidual layers / work steps havebeen reduced to a minimum.

Fast waterproofing systemsfor all applications

Three applications – three times a high level of security at a fastwork pace. All three systems forthe restoration of damp or respec-tively wet substrates are shown in the pictures sequences 1–3. Thetime sequences are oriented onthe average job performance of anemployee and an area of 5 m2 ofwall to be restored.It becomes evident that, depend-ing on the waterproofing loadcase, a significant area coverage ismade possible, which up to nowcould not be reached using tradi-tional waterproofing and restora-tion plaster systems.

Quite a while ago now, the char-acteristics of restoration plasterswere outlined by the WTA-guide-line 2-2-91 “Restoration plasters”and since manifested through thecertification of restoration plas-

ters by a WTAexpert committee.Available nowsince September2003 and in effectin Germany sinceJanuary 2005, DINEN 998 “Require-ments on mortarfor masonry”, part1: plastering mor-tars closes the reg-ulatory gap to therequirements onrestoration plasters

and puts them in line with theplastering mortar groups also reg-ulated by DIN EN 998-1: normalplastering mortar, lightweightplastering mortar, patent plaster-ing mortar, one layer plastering

mortar for outside use and heat-insulating mortar.With the publication of EN 998-1,the concept of restoration plasterhas been raised to a Europeanstandard level and thus the facts –that moist and salt-contaminatedsubstrates necessitate specialcoating concepts – have been rec-ognized and accommodated.On closer inspection though, itremains doubtful whether theestablished definition of restora-tion plasters is sufficient toachieve the crucial long-termdamage-free condition of restora-tions with these products. Thenew EN 998-1 regulates the mate-rials to be used but the standardregulating the application is atpresent still in revision.

The new standard regulating restoration plasters:EN 998-1

At night, when metro operationswere suspended...

KÖSTER KB-Pur® 2 IN 1

Waterproofing in the metro system of AthensAthens has a metro system since1869. Until 2000, there was onlyone line. With regard to theOlympic Games in 2004, two morelines were built. Monastirakistation was, due to the densebuilding development, the trafficand ground conditions and mostof all due to the archaeologicaldemands – situated in the heartof Athens at the foot of the Acro-polis – an exceptional technicalchallenge.

High requirements were placed onthe water-tightness of stationconcourses. Despite the technical-ly good construction, it was notpossible to exclude constructionjoints and leakages on cable feed-throughs which were subsequent-ly concreted. In various places,water seepages were found whichhave repeatedly been injectedduring the last months with injec-tion foam. Yet, very shortly after-wards it became apparent in thesame places that the appliedfoam had disintegrated or shrunkand thus provided new channelsfor the water.

In the end of 2005 it was decidedthat the waterproofing would bedone using the new KÖSTER KB-Pur® 2 IN 1 which would be inject-ed during the night from 1 a.m.on – after metro operations ended for the day – using a low pressuresystem.

Why KÖSTER KB-Pur® 2 IN 1?

This product combines thefeatures of an injection foam andan injection resin. The material

acts as waterstopper and solidresin in one prod-uct. Thus, on siteonly one materialis needed nowwhich provides alasting solutionfor water bearingas well as for drycracks.

Constructionjoints – water-tight at last

The foam, whichhad already been injected repeat-edly into the construction joints,was worn down by movements of the building structure and thus let water pass through after arelatively short time.After installation of the injectionpackers, KÖSTER KB-Pur® 2 IN 1was injected in the first work stepuntil the material began to dis-charge from the substrate.

Since there was still water in thecrack area, the injected materialreacted immediately to form awater stopping foam. Within thepot-life of the material, the crackwas injected again in a secondwork-step. This way, the crack areacould be permanently sealed with

an elasticresin. Inci-dentally, allconstruc-tion jointswere located below the groundwater level and thus had to bewaterproofed against flowingwater.

Injection using a low pressure system

ProfileObject: Monastiraki metro station

Technical data: Length: approx. 150 mWidth: approx. 15 mDepth: approx. 30 m

Passenger volume at peak times up to 40,000 people per hour

Developer: Attiko-Metro metro-company, Athens

Technical advice: GEO INVEST – Real Estate Construction & Trading Company SA,sole agency of KÖSTER BAUCHEMIE AGin Greece

Products used: KÖSTER KB-Pur® 2 IN 1 injection resin

KÖSTER WaterproofingReport | 4 /5

ON SITE

The subsequent waterproofingagainst rising damp in restorationand maintenance of buildingsgains more and more importance.Via the porous network of capil-lary system within a certain build-ing material, damp can rise in the masonry. Thus, considerabledamage can develop on buildings.

Once such damages and the in-filtration of damp are diagnosed,building owners, planners andapplicators are faced with ques-tion of choosing a restorationmethod. Crucial for the rightwaterproofing system are twocharacteristics:1. the degree of moisture

penetration

2. the extent of saltcontamination (quantitativeand qualitative),

which are determined by measur-ing tests. The appropriate water-proofing system can be chosenonly after this building diagnosiswas evaluated.

Do test certificates provide a design and execution guarantee?

Unfortunately not – since one istheory and the other is practice.To provide a certain security, WTA[Scientific & Technological studygroup for the restoration of build-ings and preservation of monu-

ments] developed the guideline 4-4-04/D, “Injections in masonryagainst capillary moisture”. Itis supposed to give planners andapplicators the opportunity toassess the customary injectionmaterials with regard to their features and fields of application.Proof of suitability for masonrywith various degrees of damploads (degree of moisture pene-tration: 60% – 95%) can be sup-plied.

We, the KÖSTER BAUCHEMIE AG,contracted the material testinginstitute in Leipzig, Germany inthe beginning of 2004 to carryout testing of our product KÖSTERCrisin® 76 according to WTA

KÖSTER Crisin® 76

Subsequent installation of horizontal barriers –reliable in design and applicator-friendly down to the details

Description KÖSTER Competitor Competitor CommentsCrisin® 76 Product 1 Product 2

Size of test sample fulfilled fulfilled fulfilledl: 740, h: 570, w: 240 [mm]

Alkalisation of masonry no yes not specified 1required after injection

Alkalisation of masonry no no not specified 2required before injection

Drying of masonry no no not specified 3required (before injection)

Degree of moisture penetration 89 % not specified not specified 4

Material consumption 1.2 – 1.5 litre 8 – 12 litre not specified 5(Projection of consumption per m2) (6.7 – 8.3 litre) (45 – 67.5 litre)

Completely airtight yes no no 6packaging of test pieces

Injection system unpressurised pressurized pressurized 7

Water-soluble no yes yes 8

guidelines. In comparison to otherinjection materials, the followingwas observed:

Comments:To 1) With some injection materi-als, an additional after-injectionwith an alkaliser (e.g. alkali sili-cate) is necessary. This is not thecase with KÖSTER Crisin® 76.

To 2) This is necessary if an injec-tion material is applied whichrequires alkalinity of the buildingmaterial. E. g., alkali silicates canonly penetrate the building mate-rial optimally if the building mate-rial is alkaline. KÖSTER Crisin® 76contains no alkali silicates.

To 3) Certain systems require thatthe degree of moisture penetra-tion is strongly reduced prior tothe application by heating up thebrickwork. This way, the degree ofmoisture penetration is reduced e. g. from 95% to almost 0% sothat the substance can be inject-ed. With KÖSTER Crisin® 76 thisdifficult and time consuming taskis not necessary.

To 4) The degree of the moisturepenetration of the test piece canonly be set with a tolerance of 5 – 10 %, during testing it can bedetermined exactly though. In thetest report for KÖSTER Crisin® 76,this value was determined toexactly 89 % while in the reportsof others no values are specified.

To 5) Very big differences can beobserved regarding the consump-tion of material. Material con-sumption of KÖSTER Crisin® 76 isup to 7 times lower than that ofour competitors products.

To 6) While the KÖSTER Crisin® 76

test piece was packaged com-pletely airtight, it can be noted inother test reports that the frontsides of the injection pieces werenot sealed air-tight. Just throughthis, the degree of moisture pene-tration is reduced. Obviously, acorrect test result can only beachieved with a test piece whichwas sealed airtight. Furthermore,it can be recognized by this thatthe applied water-mixable prod-ucts only develop their actualhydrophobicity once they havefallen dry. KÖSTER Crisin® 76passed this test even without thispossibility to dry up! This is impor-tant since in real-life applicationsbuilding very often stay damp.Thus, KÖSTER Crisin® 76 will stoprising damp in these cases where-as other materials will not.

To 7) In my opinion, pressurizedinjection always bears the risk ofuncontrolled outflow of the materi-al. Normally masonry is heteroge-neous and can contain cracks andcavities. Under pressure, the injec-tion material will vanish in thecracks and cavities without sealingthe area which was intended to besealed. In contrast, KÖSTER Crisin®76 applied pressureless with theKÖSTER Suction Angel System,ensures homogeneous penetrationof the material, using the capillarityof the pores which caused the risingof moisture to begin with.

To 8) Some products can be pre-set to the degree of moisture penetration of the wall by dilutingthem with water. But due to thevarying degrees of moisture pene-tration in one building, the exactrequired degree of dilution is verydifficult for the worker to adhereto. KÖSTER Crisin® 76 can not bediluted with water. When KÖSTER

Crisin® 76 is applied, no furtherwater is added into the buildingstructure.

Conclusion: In praxis, plannersand applicators demand easy to apply products which offer themost security possible. Pleasejudge for yourself on the basis ofthe characteristics described – you know our recommendation:

When making your choice, pleaseconsider the following: in build-ings which are to be restoredoften salts such as sulphate, chlo-ride, nitrate etc. are present whichare harmful to the building sub-stance. Many of the productswhich can be used to install sub-sequent horizontal barriers reactto high salt contents or can notbe applied in these situations. Incertain cases, this already beginsat 1 % (by mass) of salt content. Aproduct such as KÖSTER Crisin® 76reacts fully independent of thesesalt contents.

Non-pressurisedinjection system –safe and applicator-friendly:KÖSTER Crisin® 76

KÖSTER WaterproofingReport | 6/7

RESEARCH AND DEVELOPMENT

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KÖSTER BAUCHEMIE AGDieselstrasse 3 – 10, 26607 AurichTelephone +49 49 41 97 09-0info@koester.eu, www.koester.eu

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Meinders+Winter Werbeagentur GmbHMeindersstrasse 1, 33615 Bielefeld

KÖSTER BAUCHEMIE AGDieselstrasse 3 – 10

26607 AurichGermany

Fax number +49 49 41 97 09 40

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Fast systems for waterproofing from the inside

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Restoration plasters and EN 998-1

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Waterproofing in the metro system of Athens

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Subsequent horizontal barriers

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