ready 1 Copyright notice Unauthorised copying of this presentation as whole or in parts in any form or by any means, electronic, photocopying, recording or otherwise, without prior written permision is prohibited. “Rock grouting in extreme geological and weather conditions on Iceland and Turkey – technical problems, innovative solutions, safety, economy” Part 65 “Rock grouting in extreme geological and weather conditions on Iceland and Turkey – technical problems, innovative solutions, safety, economy” NORDIC SYMPOSIUM OF ROCK GROUTING November, 2009 (Part 65, PP 2003, animation+p/r )

2 2 Location of the projects Breiđalsheiđi and Botnsheiđi Project Kárahnjúkar Hydropower Project Héðinsfjarðargöng Project ready

3 Problems with cement based grouts due to low temperature Climate ready

4 NW corner of Iceland close to Ísafjörður ready Ísafjörður press Rock groutability press

(Héðinsfjarðargöng) ready PU resins

6 Fault 1 Fault 2 press ready l/sec !!!

7 fault Rock grouting in Breiđalsheiđi and Botnsheiđi (Iceland) water ready Water pressure ~ approx. 60 bars Water inflow ~ 50 l/sec/hole Water temperature ca. +20 ºC X Cement grouting 6m/sec !!!

low temperatures Convenient in low temperatures 8 ready press

2-component polyurethane system or mineral component (sequential grouting) 9 Component B - polyisocyonate Component A - polyols Component A+B ready One-component PU resins press

Polyurethane ≠ foam Polyurethane resins aqua-reactive PU resins Polyurethane resins are not foams- aqua-reactive PU resins the only proper name is the only proper name of this grouting material Semi-rigid foam Solid material 10 ready

PU Free PU foaming from the laboratory cube PU Free PU foaming from the cavern in the rock PUlimited water supply PU semi-solid final form with limited water supply PU PU semi-solid final form with limited water supply 11 ready

PU PU grouted joint PU PU grouted cracks 12 ready Kárahnjúkar Headrace Tunnel

PU Stone from the face grouted with PU PU resin - solid form like amber of PU resin (Ólafsfjörður Tunnel) PU Stone from the face grouted with PU PU resin - solid form like amber of PU resin (Ólafsfjörður Tunnel) PU Large fault grouted with PU (Ólafsfjörður Tunnel) 13 ready

14 None groutablecement grout None groutable rock- note small piece of cement grout PU PU grouted sandstone PU PU grouted pores in scoria PU Gravel ”cemented” with clay after PU grouting - fill partially penetrated and partially fractured ready

clay Wide fault (coobles cemented with clay) Kárahnjúkar Headrace Tunnel Water:+1°C÷+65°C 15 ready

Coarse grained crushed material, PU well “cemented” with hard clay after PU grouting Permeation grouting PU PU permeation in sand and gravel (low pressure grouting) 16 ready

urea – silicate foam Minova GeoFlex Fracturing grouting with urea – silicate foam Minova GeoFlex (stage 1) PU Minova CarboPur WF and PU Minova CarboPur WF (stage 2) clay Minova GeoFlex Minova CarboPur WF ready

Water inflow into Icelandic rock mass: - Ólafsfjördur Tunnel ready

19 Wash-out of the fill from the fault ready

SPECIFIC CARACTERISTIC IN PRACTICAL APPLICATION WILKIT FOAM T GEOFOAM PUMPING SYSTEMSIMILAR INJECTION RATIO1/1 EXPANSION RATIO (V) FILLING DRY HOLES AT 10º C AT 25º C V 20 V 40 V 15 V 30 RATIO OF PERFORMANCE IN VERY HIGH WATER FLOW AS SEEN IN KARAHNJUKAR %> % COUNSELLED TO INJECT AGAINST HIGH WATERFLOWS ++++ TOUGHNESS OF FOAM++++ FIRE PROTECTION EURO CLASS B2 → OMR Solution chosen → urea – silicate foam (OMR = Organo-Mineral-Resin) 20 ready

ready The Great Melen Project in Istanbul (TBM) - water ingress cutt-off grouting - water ingress before cutt-off grouting %

ready Cutt-off membranesOMR Cutt-off membranes with OMR 22

ready OMR Cut-off grouting (proof grouting) with OMR 23

24 Factor λ material grouted material still remaining ground water velocity = relation between volume of material grouted / material still remaining in the rock mass after hardening vs. ground water velocity in mm/min WilkitFoam, GeoFoam λ = 15÷30 x CarboPur λ = 3÷5 x De Neef Scandinavia AB 1991 wash-out effect 15 mm/sec λ ground water velocity ground water velocity [mm/min] ready presspress

25 Material cost in Kárahnjúkar: OPC 0.30 €/litre (wct = 0.67) PU 5.50 €/litre PU / OPC ≈ 18 x Relative material volume cost of various grouting products 15x Garshol 2003 ready cements PU

26 cement particles water ready Water is enemy to cement based grouts (dilution) (dilution)

27 water polyurethanes ready PU resins love water for reaction

28 faults Grout consumption in Kárahnjúkar: cement grout polyurethane resin cement grout / polyurethane resin ≈ x 10÷15 / borehole PUcement grout Lugeon value Consumption PU and cement grout vs. Lugeon value De Neef Scandinavia AB 1991 x 18 PUl/m Lugeon value cement grout l/m ready

29 Pneumatic- drive piston pump 2-comp. PU Minova CT-GX 45-II for 2-comp. PU cementitious suspensions Grouting plants for cementitious suspensions Cement grout hours Cement grout l: pumping time ca. 9 hours (20 l/min) hours hardening time = hours PU resin 4-5 hours PU resin l: pumping time ca. 3 hours (6 l/min) hours hardening time = 4-5 hours Garshol 2003 USD USD $ Δ = 15 hours / 24 hours x $ → $ ready presspresspress To get the same result……

30 ready cement grout and/or PU Final conclusions: cement grout and/or PU Cement grouts PU 1. Material volume cost [litres]: 1 x Grout consumption [m 3 of rock] x Additional daily costs $ - 4. Winter conditions (temp ºC) 5. High water velocity 6. “Conductivity contrast” rock 7. Grout penetration in rock with hydraulic conductivity < Lu ≈ hydraulic conductivity < Lu ≈ presspresspress

ready press Cement grout in common opinion as a “safe” grout ???

Certificates 32 ready

33 ready RATIO OF GROUT PERFORMANCE IN VERY HIGH WATER FLOW AND LOW TEMPERATURE PU> % PU > % OPC < 20% OPC < 20% 3 factors affecting successful and safe grouting: Proper, 1. Proper, highly qualitative material. Proper 2. Proper Method Statement. Experienced 3. Experienced Grouting Team. press 10% PU 80%OPC 80% OPC

Thank You for Your attention! Ph.D Civ. Eng. Tomasz Najder Senior Consultant Senior Consultant Movägen 3, SE Saltsjöbaden - Sweden Tel:Fax: Tel: 0046 (0) Fax: 0046 (0) Mobil: Mobil: 0046 (0) Org. no: – 2148 ready 34