1. (Part 9-2e, PP 2007, animation+p/r: 2008.03.14 rev. 2012.12.31 compr.
Part 9-2e Rock injections in Kárahnjúkar-Iceland Contact grouting for plugs
XII-2012
(Part 9-2e, PP 2007, animation+p/r: rev compr.
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.
ready

2. Family and company history in civil engineering
NAJDER engineering® is a consulting company as well as a specialist contractor within civil and foundation engineering.
We are preparing technical concepts, design projects, analyses and performing jobs as a subcontractor.
Tomasz Najder joined in the period of Skånska Cementgjuteriet (today Skanska AB) as a member of Supervising Team on the project “Second Dry Dock in Gdynia Shipyard”.
Tomasz Najder gained his experiences in Stabilator AB (daughter company in Skanska Group) as site manager, project manager and internal consultant (”trouble-shooter”), as Production Manager (Stabilator AB- International Division in Poland), in Polish-Swedish company Stabilator Sp. z o.o. (Skanska Group) as Vice President and Executive Manager.
Anna Elżbieta Najder (wife) owned Polish company Polibeton Sp. o.o. and now Swedish Najder engineering® since 1997 (until 2005 operating as Polimark International) – operating globally.
Anna Monika Najder (daughter) together with Tomasz Najder (as the President of the Board and Executive Manager) owned Polish Najder engineering® operating in Poland.
Family Najder is working within mining, tunneling and civil engineering since six generations.
ready

3. Foundation engineering and soil investigations.
Field of activity
Foundation engineering and soil investigations.
Reinforcement of existing foundations (underpinning) of industrial buildings, housing estates and ancient monuments (piling, anchors, injections).
Tunneling, rock stability and soil improvement (deep mixing method, high/low-pressure injection, lime-cement columns).
Stabilization of slopes and embankments (geogrids, soil reinforcement, drainage, geotextiles).
Sealing of existing embankments, dams, dikes and waste deposits. Flood defense. Coast protection.
Biological engineering, gabion constructions.
Leakage and moisture counteraction (insulations, drainages, sealing injections, dilatation repair) in concrete and brickworks structures.
ready 3 3

4. Daughter Anna Monika Najder 1978 -
Senior Tomasz Najder 1951-
Son Jan Najder
Daughter Anna Monika Najder
Mama Anna Najder
ready

5. Kárahnjúkar Hydropower Project 2006-2008
Diversion Tunnels at dam 2.4 km (Kar 14)
Headrace Tunnel 53.0 km (Kar 14)
Grouting galleries at dam  0.5 km    (Kar 14)
Cable tunnel  km
Hraun Diversion 2.0 km
Grjótá Diversion km
Adit km (Kar 14)
Adit km (Kar 14)
Adit km (Kar 14)
Surge Tunnel km (Kar 14)
Drainage Tunnel 0.7 km (Kar 14)
Penstocks km (2x)
Access to Powerhouse 1.0 km
Tailrace Tunnel km
Total Tunnel Length: 73.0 km (D&B=10 km, TBM=63 km)
press
press
ready
Kárahnjúkar Hydropower Project 5 5

6. Main Dam area – view from the canyon
ready

7. Main Dam
ready

8. HRT
Kárahnjúkar (“Windy Mountain”)
ready
Headrace Tunnel 8

9. Jökulsá Diversion Tunnel
Main Dam
Jökulsá Diversion Tunnel
HRT
Powerhouse
Powerhouse area
ready 9

10. TBM
D&B
press
ready

11. The TBM is composed of the following main components: - Cutter head
- Main beam
- Gripper system
- Thrust Cylinders
- Rear Lift Legs
- Tow System
Accessories:
- Roof Bolting and Probe Drilling Rigs
- Ring Beam Erector
- Core drill
- Shotcrete system
- Back-up
- No. 9 decks
- Rolling stock Locomotives and service wagons
ready

12. Main Dam under construction – view from Kárahnjúkar (“Windy Mountain”)
ready

13. Kárahnjúkar Dam – cross section
ready

14. Kárahnjúkar Dam – diversion tunnels, Power Intake and spillway
HRT
Kárahnjúkar Dam – diversion tunnels, Power Intake and spillway
ready

15. Plug (Main Dam)
ready

16. 8m long pre plug and 16,6m long Plug 5 in Diversion Tunnel T2
ready

17. 8m long pre Plug 5 in Diversion Tunnel T2 ready

18. Cooling system against cracking
at Plug 5
ready

19. Cooling system against cracking: temperature increase after pouring
of Plug 5
ready

20. Curtain grouting with cement grout at Plug 5
ready

21. Consolidation grouting with cement grout at Plug 5
ready

22. Plug 5 – grouting pattern for consolidation- and contact grouting
press
ready

23. ready
and cracks in concrete

24. Contact grouting with cement grout
above the pre plug
ready

25. Plug 5 – drilling for contact grouting within the plug
ready

26. Contact grouting with cement grout above the plug
ready

27. Contact grouting. Note water coming
through the early-age thermal crack.
None-succeeded cement grouting for crack repair
ready

28. Concrete repairs (the early-age thermal crack): holes with packers ready for grouting with polyurethane resin (PUR)
ready

29. Concrete repairs (the early-age thermal crack):
PUR grouting at the crown of the plug
ready

30. Concrete repairs (the early-age thermal crack): PUR grouting completed
ready

31. Headrace Tunnel excavation – longitudinal section
ready

32. Headrace Tunnel profile

33. Curtain, consolidation and contact grouting
Grouting for plugs
(Headrace Tunnel)
Curtain, consolidation and contact grouting
ready

34. Main junction
Plugs
press
press
press
ready

35. Rock fractured after blasting
ready

36. Typical plug construction
(Adit 2 Plug 2.2 with door)
ready

37. Clay filled fault across Plug 2.2
ready

38. Drilling for curtain grouting (stage 1a) (Adit 2 Plug 2.2 with door)
ready

39. Drilling for consolidation grouting (stage 2a)
(Adit 2 Plug 2.2 with door)
ready

40. Packers for curtain grouting with cement grout (stage 1b)
and for consolidation grouting (in front of the plug – stage 2b)
(Adit 2 Plug 2.2 with door)
ready

41. Packers for curtain grouting with cement grout (stage 1b)
(Adit 2 Plug 2.2 with door)
ready

42. Mechanical packers for cement grouting
(Adit 2 Plug 2.2 with door)
ready

43. The crack in the concrete caused by too high grouting pressure
and leaking cement grout !!!
(Adit 2 Plug 2.2 with door)
ready

44. Contact grouting (stage 3b) with 2-comp. PUR
(Adit 2 Plug 2.2 with door)
ready

45. Contact grouting (stage 3b) with 2-comp. PUR
(Adit 2 Plug 2.2 with door)
ready

46. Contact grouting (stage 3b) with 2-comp. PUR
(Adit 2 Plug 2.2 with door)
ready

47. Result of contact grouting (stage 3b) with 2-comp. PUR.
The crack in the concrete caused by too high grouting pressure
(Adit 2 Plug 2.2 with door)
ready

48. Crack filled (repaired) with 2-comp. PUR
(Adit 2 Plug 2.2 with door)
ready

49. Door to Headrace Tunnel completed
(Adit 2 Plug 2.2)
ready

50. Typical plug construction
(Plug 4 with door)
ready

51. Grouting pattern
(Plug 4 with door)
ready

52. Drilling for curtain grouting (stage 1a)
(Plug 4 with door)
ready

53. Steel grouting pipes with valves for contact grouting
(Plug 4 with door)
ready

54. Steel grouting pipes for valves Mixed system for contact grouting
Mechanical packers
Steel grouting pipes for valves
Mixed system for contact grouting
(Plug 4 with door)
ready

55. Mechanical packers for contact grouting
(Plug 4 with door)
ready

56. Drilling pattern for contact grouting with PUR
(Adit 3 Plug without door)
ready

57. Scaling of rock above the planned concrete plug
(Adit 1 Plug with door)
ready

58. Mechanical packer for curtain cement grouting (stage 1b)
(Adit 1 Plug with door)
ready

59. 0,20-1,0 m
Contact grouting with cement grout through steel pipes placed in the formwork before pouring the concrete (Adit 1 Plug with door)
press
ready

60. Contact grouting with cement grout through steel pipes
(Adit 1 Plug with door)
ready

61. Contact grouting with cement grout
through steel pipes
(Adit 1 Plug with door)
ready

62. Contact grouting with cement grout
return circuit
to the packer
Contact grouting with cement grout
– equipment for keeping certain refusal pressure
(Adit 1 Plug with door)
press
ready

63. Leaking early-age thermal cracks
(Adit 1 Plug with door)
ready

64. Plug 1 after completion of cement grouting
press
ready

65. Leakages after completion of contact grouting using cement grout
ready
Leakages after completion of contact grouting using cement grout
(Plug 1 with door)

66. Water ingress through new probe drill hole
(Adit 1 Plug with door)
ready

67. Consolidation and contact grouting with 2-comp. PUR.
Note water leakages through the cracks in concrete
(Adit 1 Plug 1 with door)
ready

68. Consolidation and contact grouting with 2-comp. PUR.
Note water leakages through the cracks in concrete
(Adit 1 Plug 1 with door)
ready

69. Leaking interface between rock and the concrete, cracks and joints
before and after PUR contact grouting
(Adit 1 Plug with door)
press
ready

70. Leaking interface between rock and the concrete
before and after PUR grouting
(Adit 1 Plug with door)
ready

71. Leakage at the door
ready

72. Outlet of grouting hoses for resin post grouting
ready

73. Drainage Tunnel Plug
ready

74. Drainage Tunnel Plug (to the left) – note grouting pattern for curtain grouting
ready

75. Drainage Tunnel Plug – note grouting pattern for consolidation grouting
ready

76. Drainage Tunnel Plug – consolidation grouting drill pattern
and contact grouting pipes
ready

77. Mini drill rig for rotary-percussive drilling
ready

78. Cement grouting with Bimbar packer
ready

79. Grouting pipes with return valves
for contact grouting
with cement grout
ready

80. Grouting pipes with return valves with cement grout – details
for contact grouting
with cement grout – details
ready

81. Steel pipes for for contact grouting with cement grout
ready

82. Drainage Tunnel Plug – pouring of concrete
ready

83. Bad poured concrete plug
ready

84. Main Dam under construction by Tom Olliver
ready

85. Thank You for Your attention!
THE END
Thank You for Your attention!
ready

86. Welcome to www.najder.se
ready