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Contents of the presentation
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The main areas of use for injections in
underground construction and mining
Water ingress is too big for cementitious Ground improvement required within very short
injections (grout is flushed away before setting) time (a few minutes)
Unexpected and often uncontrolled situations When a collapse situation is imminent and very
Rapid reacting and foaming resins often high mechanical strength can immediately
required resolve the situation
Coal mining
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Four main categories of injection
technologies to solve problems
5
Understanding the problem, selecting
the right injection technology
8
Ground consolidation and water
ingress reduction in underground
constructions
9
Ground consolidation and water
ingress reduction
10
Cementitous grouts
Main available types
11
Size matters!
12
Particle sizes
13
An important cost-benefit with
RHEOCEM microcements:
S I L T S A N D G R A V E L
90
80
Percentage Passing
70
60
50
40
30
20
10
0
0.001 0.01 0.1 1 10 100
MIXER PUMP
Packer
AGITATOR TANK
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Injection plant
Häny compact unit
Can be used for all types of injection cements
as well as colloidal silica
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Modern equipment for large scale
pre-injections: new injection rig
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RHEOCEM in big bags: Logistics
for large scale pre-injections
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NEW! Controlled accelerated setting of
microcement
COLLOIDAL
AGITATOR
MIXER
TO GROUTING LOCATION
INTERFACE
ADDITIVE
PUMP
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Cement based injections; adding
additives to manipulate grout properties
Alcali
SA 160free
accelerator
Rheocem
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Injection with unaccelerated grout
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Injection with controlled accelerator dosage
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Colloidal silica for ground
consolidation and water ingress
reduction
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Colloidal Silica Technology
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Viscosity over time
1000
800
Viscosity (cP)
600
Collision
400
start
200
0 10 20 30 40
Time (min)
29
Compressive strength over
time
Ongoing reinforcement
Uniaxial compressive strength
140
120
100
(N/cm2)
80
60
40
20 Coalescence start
0
0 100 200 300 400 500 600 700 800 900 1000
Time (days)
30
Colloidal silica:
Strength development over time
1200
Uniaxial compressive strength
200
0
0 10 20 30
Time (days)
Testing of uniaxial
compressive strength 0.4
MPa
Results from lab, show the
same level of strength
0.45
MPa 32
Colloidal silica for injections from BASF
- MEYCO MP 320 group of products
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Main properties colloidal silica
pH <11
Content: water, SiO2 and Na2O < 0,7. (Water-glass has > 7)
Other applications: Water treatment, clarification of wine and juice,
coatings, polishing of silica wafers
Silica sols are Reinheitsgebot approved in Germany and used in
the beer production
Not classified product, see the MSDS
Catalyst (accelerator) : Salt NaCl and water, in the grout mixture,
which has a lower salt concentration than the North Sea!!
Not classified product, see the MSDS
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Colloidal silica : a better choice than
silicate (waterglass) gel
160
150
140
Gel time (minutes)
120
100
80
60
56
40
31
20
18
11
0
10 15 20 25 30
Values at 8°C
Accelerator % by volume
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Colloidal silica
Where to use?
Consolidation of sand, silt and weak rock where microcement can not
penetrate
As “fine” injection after being first injected with microcement to take the
last drops of water
Slope stabilisation
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Colloidal silica: stable gel
No shrinkage in humid conditions
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References colloidal silica
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MEYCO MP 320 Colloidal Silica
Consolidation of weak sandstone in Portugal
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Maneri Bhali hydropower, India
Pre-injection for water ingress reduction and
ground stabilisation
Injection of RHEOCEM
650 and MEYCO MP 320
colloidal silica
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Colloidal silica pre-injection :
Törnskogstunneln, Stockholm
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MEYCO MP 320 colloidal silica:
High speed rail tunnel Bologna
Contractor :
San Ruffilio S.c.r.l.
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MEYCO MP 320
Limmerick, Ireland
Soft gravely
clay
Peat
Perforated steel
Soft silty clay injection pipes installed
6m concrete into sand. Length ~2m
segment shaft
Soft gravely TBM advance
clay after injecting
Loose,silty MP 320
sand
Sandy gravel
Gravel and
boulders
Modern pre-injection in
underground construction
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What is pre-injection?
Pre-injection
Post-injection
Tunnel
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Pre-injection
Typical length: 15 to 30 m
Typical spacing: 1 to 2 m
5m
~9m
5m
~ 15 m ~6m
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Why pre-inject?
Safety
Environment
Cost
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Water ingress in tunnels and
mines
Safety
One of the largest
problems in tunnels is
uncontrolled water ingress.
Two of the biggest risks
are
Immediate flooding
Ground collapse
associated with water
ingress
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Water ingress in tunnels and
mines
Environment
Environmental
concerns is another
issue
Contaminated water
has to be managed
Lowering of ground-
water has to be
prevented in most
areas
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Water ingress in
Water in tunnels tunnels and
mines
Cost
Pumping water is huge
cost (e.g. sub sea tunnels)
Reduced tunnel
production
Can put a stop on work for
shorter or longer periods
of time
Right focus: Not kg price,
but time consumption
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Relation between
pre-injection and post-injection
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Drilling for injections ahead of the
TBM
A systematic method to stop water ingress
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Lofast road tunnel, Norway Groundwater 3 oC and with high
pressure, open water bearing joints
Pre-injection with accelerated microcement grout for rapid setting in cold water
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Jong - Asker Norway
Double track rail tunnel
OPC: 862kg
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Oset Drinking water plant -
Oslo
2 Caverns: 136.000 m3
excavated rock volume
Allowed seepage into caverns:
100 l/min
Result: 20 l/min
Consumption of injection
materials:
Local OPC: 820 tons
RHEOCEM 650: 1510 tons
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Liquid propane storage rock cavern,
Norway
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Coffee break
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Rapid ground consolidation
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Rapid ground consolidation
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Stabilizing of fault zones in coal mines 65
Avoid face collapse in coal mines 66
Stabilizing of soil in tunneling
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Urgent need for ground improvement
Collapse situations
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Injection with chemical grouts
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Injections for rapid water
ingress reduction
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MEYCO urea silicate resins
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Injection with chemical grouts
A B
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Rapid reacting resin for ground improvement
MEYCO MP 364 Flex
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Injection with chemical grouts
Boarder time: Time needed to reach 1 MPa bonding strength in lab conditions 76
Injection with chemical grouts
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Rapid ground consolidation
MP 364 Flex
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Injection with chemical grouts
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Injection with chemical grouts
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Injection with chemical grouts
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Rapid reacting foaming resin for void filling and
ground consolidation
MEYCO MP 367 Foam
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Void filling to improve stability
MP 367 Foam
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Urea silica resins
MEYCO MP 364 Flex, MEYCO MP 367 Foam
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Injection with chemical grouts
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Rapid ground consolidation in mining with two
component PU system
MEYCO ® MP 358 SC & GS
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Injection with chemical grouts
A B
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Rapid ground consolidation with
foaming high-strength resins
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Rapid ground consolidation with
foaming high-strength resins
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Polyurethane resins
MEYCO MP 358 SC & GS
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Rapid water ingress reduction
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Injection for rapid water ingress
reduction
Injection systems, which give a high volumetric foam expansion in
short time when in contact with water
Typical use in situations where there is an urgent need to eliminate
water ingress points
Cement-based systems are too slow
Highly reactive chemical resins are required
Reaction speed : down to 20-30 seconds
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MEYCO polyurethane resins for
water stopping
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MEYCO polyurethane resins for
water stopping
Group of products MEYCO MP 35X
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References rapid water ingress
reduction
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MEYCO MP 355 A3 THIX FAST injections for
water stopping, Karahnjukar HEP Iceland
2-component polyurethane
resin, rapid in foaming
Is a customized technical
solution with support from
CONICA in urgent cases
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MEYCO MP 355 A3 THIX FAST, 2-component PU,
a combination of injection and drainage
Injection holes
Drainage holes
A B
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Karahnjukar, Iceland:
Injection set-up on California switch
Injection equipment
California switch
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MEYCO MP 355 A3, 2-component PU
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MEYCO MP 355 A3, 2-component PU for
refurbishment of masonry lining
Rehabilitation of old
masonry tunnels
Croatian Railroads
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MEYCO MP 355 1K, 1-component PU
Typical area of use : Water stopping injections
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Injection equipment
&
site installation
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Polyurethanes and urea silicates
Equipment setup
Site installation
flushing hoses
air hose
Connect the flushing hoses with the pump and place them in the proper
barrel.
Be careful not to place them into the wrong barrel
conveying hoses DN 20
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Polyurethane injection
Layout of mixing head for two components
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Injection with chemical grouts
Application
Site installation
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Injection with chemical grouts
Pump set up
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Injection with chemical grouts
A B
air hose
A to A
suction hoses
B to B
conveying hoses DN 20
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Injection with chemical grouts
Pump
Connect pump to energy
Air driven pumps always need enough oil
Connect pump with the resin storage containers
Hoses A to the white container, B to the black container
Pump and container are signed in white and black
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Injection with chemical grouts
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Injection with chemical grouts
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Injection with chemical grouts
The static mixer and other parts may occasionally become clogged
(enough spare parts)
Stationary pumps: only the mixing head and the mobile hoses have to be
cleaned
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Health & Safety
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Injection with chemical grouts
BASF MSDS provide all the needed information for the safe handling of
the products
For a variety of products additional application recommendations can be
found in the method statements
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Injection with chemical grouts
Storage
Canisters and/or containers must be stored in places where they cannot
be damaged
Avoid damage of the container floors
Damage of the resin containers by rock fall is to be prevented
Canisters and/or containers must be placed safely and horizontally
Always think of the storage temperatures listed in the TDS
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Injection with chemical grouts
Transportation
Canisters and/or the containers must be transported in a way that
definitely rules out damage during the transport
To prevent them from being damaged or crushed
Propping or bracing the containers may also help to prevent them from
slipping
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Injection with chemical grouts
Processing
A safe, clean and well-lit work place helps to prevent leakages or
splattering
Avoid skin contact
The ground should be free from sharp obstacles
Enough space should be available
Canisters should be completely emptied
Canisters and/or containers containing residual quantities of material
must be closed
Formation of aerosols must be prevented
Synthetic resins are not to be sprayed
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Injection with chemical grouts
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Health & Safety
Introduction
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Health & Safety
Introduction
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Injection with chemical grouts
Body Protection
Disposable paper overalls have proven
suitable as body protection
They can be easily worn over the regular
working clothes
paper overalls do not provide
permanent protection
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Injection with chemical grouts
Hand Protection
Hands are best protected by wearing suitable gloves
Sufficiently tight and resistant against the individual
components and the synthetic resin
Manufacturer’s MSDS provides the information on
which type of gloves are best suited
Rubber gloves are most frequently recommended
Leather or textile do not provide sufficient protection
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Injection with chemical grouts
Eye Protection
Injected grout can suddenly and unexpectedly
escape from cracks
Fittings can be faulty
Eyes must be protected during the injection
Safety glasses that provide protection against
chemicals are best suited
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Injection with chemical grouts
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Injection with chemical grouts
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Injection with chemical grouts
Skin Contact
Skin contact may cause a sensitization (allergic reaction) and irritation of
the skin
Soaked clothes or shoes must be taken off
Splatters on the skin are to be dabbed away carefully with a clean piece
of cloth
Rubbing must be avoided
Do not use solvents or chemicals to remove the product from the skin
If large areas of the skin have come in contact with the resin (bigger than
10 cm * 10 cm), medical attention must be sought
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Injection with chemical grouts
Eye Contact
Spatters to the eyes cause strong and painful irritations
Lasting damage has not been experienced
The affected eye must be rinsed with running water immediately
The rinsing must last until the stinging ceases, but at least for 10 minutes
During the injection operation, a bottle for eye-rinsing fluid must be kept
available at the site of the injection
Medical attention from an eye specialist must be sought immediately
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Injection with chemical grouts
Inhaling
Aerosols can be inhaled
Aerosols from isocyanate can irritate the mucous membrane of the nose,
throat and lungs
This can cause coughing, breathing problems, headaches and in rare
cases allergic reactions and asthma-like attacks
The affected person must be taken to fresh air immediately
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Injection with chemical grouts
Swallowing
Drinking, eating, chewing tobacco and using snuff are absolutely
forbidden
If the grout and/or one of its components have been swallowed, medical
attention must be sought as a precaution
Keep the affected person calm and do not try to encourage him to vomit
The doctor should be shown the Material Safety Data Sheet of the
swallowed product
No cases have been reported in which the swallowing of components of
synthetic resin has caused health problems
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Injection with chemical grouts
Leaks
Stop and go Injection process
Additional abutments with sprayed concrete or thin spray-on liners
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Injection with chemical grouts
At some stage during the pumping process there is the risk that
the system has a problem, this may occur due to any number of
circumstances or reasons. If unsure SHUT DOWN the entire
system by following the steps below:
Open both component valves back to the tanks
Shut off the high pressure valves
Turn off and isolate the pumps compressed air supply
Notify nozzle man
Rectify problem
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Injection with chemical grouts
Johannesburg,
South Africa
Shanghai,
China
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Injection with chemical grouts
Packaging
139
Injection with chemical grouts
Packaging
140
Repair tunnel linings with
injections
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Repair injections in tunnel linings
Masonry linings
Joints and backfill of masonry lining
Leaks
Mechanical improvement
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Application methods
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Application methods
Water is trapped
within barriers!
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Application methods
Bleed holes to
release trapped
water during
injection
Packer injection
from opposite end!
Resin replaces
water!
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Application methods
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Size and type matters…
Common packers
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Application methods
Angle ~45°
≥D/2
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Application methods
As most people do
Proper drilling depth What we recommend
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Application methods
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Viscosity matters
Water 1 mPas
Acrylate < 200 mPas water based
PU resin > 200 mPas hydrophobic
PU foam > 400 mPas hydrophobic
Epoxy > 200 mPas hydrophobic
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Find out what you really need?
154
References tunnel lining
repair injections
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Budapest Metro, rehab Line 2:
Acrylate injections behind the concrete
lining
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New tunnel linings in need of repair !
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The main areas of use for injections in
underground construction and mining
Water ingress is too much for cementitious Ground improvement required within very short
injections (grout is flushed away before setting) time (a few minutes)
Unexpected and often uncontrolled situations When a collapse situation is imminent and
immediate very high mechanical strength can
Rapid reacting and foaming resins often resolve the situation
required
Coal mining
159
The four main categories of injection
technologies to solve problems
160
Thank you for your attention
161