AECOM PowerPoint Template
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AECOM PowerPoint Template
AGS (HK) 1-day Seminar on Grouting and Deep Mixing 7 June 2014 Pre-Excavation Grouting in Hard Rock Tunnelling By Knut F. Garshol Headlines of this Presentation: 1. Why Ground Water Control? 2. Selection of Grout Mix 3. Pre-Excavation Grouting, Execution Steps 4. Special Aspects of PEG 5. Project Reference – HATS 2A 1. Grouting Results 2. Summing Up HATS2A 6. CONCLUSION 2 Why Ground Water Control? Groundwater Movement in Rock Rock material is impermeable GW contained in discontinuities GW is migrating on conductive channels Fault Zone Massive Rock Jointed Rock Conductivity contrast is an important factor in GW control considerations 4 Effects of GW Ingress Surface Settlement Underground Safety and Working Conditions Environmental Impact 5 Water in-rush at tunnel face 1 ton 6 Avoid such situations “Small lake” became smaller Back to normal 14 km Gardermoen Tunnel, Oslo, Norway 7 Experience from HATS Stage 1 1st Joint Venture: Excavated 5% of 24.5 km Stopped by Water ingress Settled in Court New tender process Stage 1 finished by the new Contractors, BUT…. With substantial delays Stage 2A: Drastically changed compared with Stage 1 8 Manual handling of drill rods & packers HATS Stage 1 9 Avoid Post Grouting! HATS Stage 1 10 D&B Advantage: Drill Jumbo HATS Stage 2A Probe hole hitting 15 bar water channel 11 Benefits of GW-Control: Risk of major water in-rush practically eliminated Gives basically dry working conditions in tunnels Substantially improved stability in poor ground Less water to pump to surface Improved conditions for permanent lining works 12 Selection of Grout Mix Purposes of Grouting Ground water control Ground stability improvement Sometimes: A combination of the above Requirements for success: A suitable grout must be injected into the ground, penetrating a sufficient ground volume to achieve the targeted effects 14 Basic Grouting “Problem” in rock 15 Selection of Grout-Mix Traditionally, locally available OPC w/c-ratio 3.0 to 1.0 mostly with Bentonite Unstable grout that needs "grout to refusal” Low-quality and poor durability grout Today, use of micro cement w/c-ratio 1.0 and lower Stable and thixotropic grouts (no bleeding) Bentonite replaced by admixtures 16 Traditional Technology – Disadvantages High w/c-ratio gives lots of water to pump High bleeding requires "pump to refusal" Gives extreme materials spreading, locally No cement enters finer cracks in first step, due to clogging before pressure increase Practically complicated (variation of w/c-ratio) Conclusion: Time consuming 17 New Technology – Advantages Stable, low viscosity, fixed w/c-ratio grout Allows dual stop criteria for injection • Maximum pressure or • maximum quantity per hole Allows high output and pressure from start Gives simultaneous penetration of small and large cracks and openings Conclusion: Time saved 18 Generally about Cement Always the Primary grout material Used as a suspension in water w/c-ratio typically between 0.45 – 1.5 (by weight) Wide range of additives and admixtures Wide range of cement types and properties Permeation capability depends on: Particle size of the cement used Viscosity (and cohesion) of the suspension Pressure stability of the suspension 19 Marsh Funnel Viscosity 20 Mud Balance 21 Water-Cement Ratio W/C-ratio = 1.0 mix Control by Mud Balance 22 Pressure Stability 23 Other important properties Initial and final set time Strength development Final strength of injected grout Stability and durability in the ground? 17 projects, 59 km of tunnel: Average 37% ingress reduction (during 10 years) 24 Pre-Excavation Grouting Execution Steps Drill & Blast with PEG After every 4th blast (typically) Probe Ahead Measure Water Inflow Temporary Support Pre-Excavation Grouting Scaling, Mucking and Geological Mapping Blasting 26 Execution Steps Systematic Probe Drilling – PEG if triggered Minimum 5 m overlap (more in poor ground) Grouting Stop Pressure 60-80 bar If not reached – Stop on Quantity Stable Micro Fine Cement Grout, Only Colloidal Silica (where needed) Overlap provides tight “bulkhead” for next probe drilling and PEG fan VERY important 27 Grout Hole Pattern Probe Holes Grout Holes Control Holes Number of holes depend on tunnel span (1-1.5 m c/c). Grout hole length (15 to 33 m). Lookout distance (5.5 m). Schematic Layout of Drilling Pattern 28 Tunnel CrossSection Construction Method – Drill & Blast + PEG Advance approx. 4 m 29 29 Automatic Rod Handling (EXAMPLE) Tamrock TRH rod-handling-system Compared with manual rod handling: Double drilling output AND Improved Safety Rod Magazine 30 Equipment Set-up - Simplified Electronic Flow and Pressure Recording Packer High-Pressure Grout Pump Colloidal Mixer 31 Agitator The Real Deal Contract 24 AMV / Häny Contract 23 Unigrout Atlas Copco 3 Pumps and 3 Grout Lines Each 32 Grouting Materials Microfine Cement Colloidal Silica •Microfine Cement •Pressure: 60-80 bar •Volume 2000 L •Colloidal Silica •Pressure: 40 bar •Volume 750 L 0.1 mm Grouting Stop Criteria MC 0.03 mm CS 0.016 μm Colloidal Silica Microfine Cement 33 Colloidal Silica OPC 0.1mm Special Aspects of PEG Safety of PEG works Hydraulic working basket Packers secured by chain Disposable Packer designed for 100 bar 35 Disposable Packers & Lances 36 Use of Standpipes in Poor Rock 37 Bag Packers in Poor Rock 38 Project Reference - HATS2A Sub-Sea Sewage Conveyance – Hong Kong Harbour Area Treatment Scheme – Stages 1 and 2A Stonecutters Island Sai Ying Pun North Point Aberdeen LEGEND Outfall Tunnels (Completed) HATS Stage 1 Sewage Tunnels (Completed) HATS Stage 2A Sewage Tunnels 40 HATS 2A Overview North Point Contract 24 Sai Ying Pun Contract 23 Victoria Habour Stonecutters Island 41 Vertical shafts: 13 Total Tunnel Length: 20 km Settlement Sensitive Reclaimed Land North Point Sai Ying Pun HONG KONG ISLAND Aberdeen LEGEND Coastline of Year 2005 HATS 2A Tunnels 42 Depth Below Sea Level North Point to Aberdeen Sai Ying Pun North Point Wan Chai East Aberdeen Cyberport Central Appx. 120 msl Appx. 150 msl Wah Fu Sandy Bay Appx. 70 msl To Stonecutters Island Crossing of Victoria Harbour Stonecutters Island Sai Ying Pun Victoria Habour LEGEND Sea Soil Rock 43 Appx. 140 msl Major Rock Types Encountered in HATS 2A Tunnels Volcanic Rock • 34% of tunnel length • Predominantly Volcanic Coarse Ash Crystal Tuff with subordinate Fine Ash Tuff • 50-percentile UCS = 240 MPa • Highly variable joint intensity and orientation Granitic Rock • 66% of tunnel length • Medium Grained Granite • 50-percentile UCS = 180 MPa Granite 66% Granite/Tuff Contact Zone Granite Tuff Tuff 34% Geological Map of Hong Kong (CEDD/GEO 2006) 44 Granite/Tuff Contact Zone T T G G T 45 G Distribution of Residual Ingress Limits In granite In tuff 50.0 Percent of Tunnel Length 45.0 40.0 35.0 30.0 25.0 20.0 15.0 10.0 5.0 0.0 5 15 30 L/min/100 m tunnel 46 50 Grouting Results Residual Ingress to Excavated Tunnels Rock Type Granite Tuff Avg L/min/100 m Avg L/min/100 m Maximum Ingress Limit 30.2 16.9 Actual Residual overall ingress 6.5 7.5 Sections within limit (92%) 4.5 6.0 Sections failed (8%) 45.3 21.6 Average values Weighted against tunnel length 48 In Granite: Very Wet & Very Dry Sections LEGEND HATS 2A Alignment Tunnel section 413 m long: Measured ingress from all 1st stage grout holes: = 9,200 L/min/100 m tunnel Measured after excavation: About 1.0 L/min/100 m (= 99.99% reduction) Cement Consumption: 1549 kg/m (= 5.7 X the granite average) Tunnel section about 1500 m: Almost dry (hardly any PEG required) Cement Consumption < 50 kg/m 49 Probe Drilling in the Wet section 1200 L/min 15 bar pressure 50 Filled Open Joints 51 Filled Open Joints - Detail 20 MPa UCS 52 Practically Dry Tunnel 13 September 2013 53 Summing Up HATS2A Summing Up HATS2A Micro Fine Cement ONLY, supplemented by Colloidal Silica Verification of result by Control Holes before further excavation Tight face “bulkhead” is a “Must” especially in soft ground 27% of tunnel length required < 5 L/min/100 m tunnel 92% of excavated tunnels well below ingress limits The Tuff required 78% more drilling ahead AND 3.7 X more Colloidal Silica than in Granite Two Main Reasons for the Success: 55 D&B excavation Modern PEG technology + Re-measurable quantities for payment CONCLUSION CONCLUSION In Hard Rock Tunnelling: Technology for Ground Water Control by PEG for Practically Dry Tunnels is currently available Very Strict Ingress Limits will require: Excavation by Drill and Blast Micro Fine Cement Colloidal Silica 57 [email protected]
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