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Ready 1 Copyright notice Unauthorised copying of this presentation as whole or in parts in any form or by any means, electronic, photocopying, recording.

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Presentation on theme: "Ready 1 Copyright notice Unauthorised copying of this presentation as whole or in parts in any form or by any means, electronic, photocopying, recording."— Presentation transcript:

1 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 4.-5. November, 2009 (Part 65, PP 2003, 2009.10.30 animation+p/r )

2 2 2 Location of the projects Breiđalsheiđi and Botnsheiđi Project 1993-1994 Kárahnjúkar Hydropower Project 2006-2008 Héðinsfjarðargöng Project 2007-2009 ready

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

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

5 (Héðinsfjarðargöng) ready PU resins

6 6 Fault 1 Fault 2 press ready 1.000 l/sec !!!

7 7 fault Rock grouting in Breiđalsheiđi and Botnsheiđi (Iceland) 1993-1994 water ready Water pressure ~ approx. 60 bars Water inflow ~ 50 l/sec/hole Water temperature ca. +20 ºC X Cement grouting 6m/sec !!!

8 low temperatures Convenient in low temperatures 8 ready press

9 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

10 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

11 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

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

13 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 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

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

16 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

17 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

18 Water inflow into Icelandic rock mass: - Ólafsfjördur Tunnel ready

19 19 Wash-out of the fill from the fault ready

20 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 40 - 50%> 80 - 90% 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

21 ready The Great Melen Project in Istanbul (TBM) - water ingress cutt-off grouting - water ingress before cutt-off grouting 21 7.439%

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

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

24 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 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 26 cement particles water ready Water is enemy to cement based grouts (dilution) (dilution)

27 27 water polyurethanes ready PU resins love water for reaction

28 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 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 19-21 hours Cement grout 10.000 l: pumping time ca. 9 hours (20 l/min) + 10-12 hours hardening time = 19-21 hours PU resin 4-5 hours PU resin 1.000 l: pumping time ca. 3 hours (6 l/min) + 1-2 hours hardening time = 4-5 hours Garshol 2003 USD USD $ Δ = 15 hours / 24 hours x 65.000 $ → 41.000 $ ready presspresspress To get the same result……

30 30 ready cement grout and/or PU Final conclusions: cement grout and/or PU Cement grouts PU 1. Material volume cost [litres]: 1 x 15 2. Grout consumption [m 3 of rock] x 18 1 3. Additional daily costs 41.000 $ - 4. Winter conditions (temp. + 3-5 ºC) 5. High water velocity 6. “Conductivity contrast” rock 7. Grout penetration in rock with hydraulic conductivity < Lu ≈ 10-15 hydraulic conductivity < Lu ≈ 10-15 presspresspress

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

32 Certificates 32 ready

33 33 ready RATIO OF GROUT PERFORMANCE IN VERY HIGH WATER FLOW AND LOW TEMPERATURE PU> 80 - 90% PU > 80 - 90% 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

34 Thank You for Your attention! Ph.D Civ. Eng. Tomasz Najder Senior Consultant Senior Consultant Movägen 3, SE-133 36 Saltsjöbaden - Sweden Tel:Fax: Tel: 0046 (0)8 717 5714 Fax: 0046 (0)8 717 6042 Mobil: Mobil: 0046 (0)704 217 012 E-mail: E-mail: tomasz.najder@hotmail.com http://najder.se/ Org. no: 490911 – 2148 ready 34

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