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Section
Method Statement for Primary and Secondary Grouting Doc No. ITD/BE1/MS/T007, Rev.
C
METHOD STATEMENT
FOR
PRIMARY AND SECONDARY GROUTING
Document No. ITD/BE1/MS/T007, Rev. C
JULY 2013
PREPARED BY:
1 July 2013
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Method Statement for Primary and Secondary Grouting Doc No. ITD/BE1/MS/T007, Rev.
C
Date
Amendment Record
15 February 2012
11 April 2012
1 July 2013
Copy
No
Distribution
List
Type of
Issue
MRTA
PMC
CSC
Recipient
Copy
No
Distribution
List
Type of
Issue
Recipient
Type of Issue
A For Internal Review& Comment
B For ERs Approval
Type of Document
Where this page is over-stamped with the words C this means:
1. Distribution is centralized-in this case from the Quality Assurance Manager.
2. Each copy is issued to a particular person or organization. If no longer required it should be returned.
3. It is not to be photocopied either in whole or in part. Additional copies are available on request.
4. Copy holders will be automatically issued with any amendments. Responsibility for incorporating such
amendments rests with the copy holder.
1 July 2013
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Method Statement for Primary and Secondary Grouting Doc No. ITD/BE1/MS/T007, Rev.
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Prepared by: __________________________
(Nopporn Rattanchayabun)
Section Manager (TBM Tunnel)
Date : ______________________
Date : ______________________
Date : ______________________
Date : ______________________
Table of Contents
1.
Scope........................................................................................................3
2.
3.
4.
Working Procedures...................................................................4
5.
6.
7.
Attachment A Grouting Material for shield Tunneling Work: Proposal for Mix Design
and Testing Method....................................................................................17
8.
Attachment B The Laboratory Test Program for Primary and Secondary Grouting
Works..27
9.
10.
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Method Statement for Primary and Secondary Grouting Doc No. ITD/BE1/MS/T007, Rev.
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1.
Scope
This method statement provides information for Primary Grouting and Secondary
Grouting in the MRT Blue Line Extension Project, Contract 1: Hua LamphongSanam Chai Section. The cavity between the segment outer surface and soil shall
be filled with grout material as soon as possible after TBM excavation. Therefore,
the cavity between segments extrados and surrounding ground will be grouted
immediately after TBM excavation suddenly after TBM move through segment hole 2
positions at shoulder left & right. This grouting shall be performed in two steps
namely primary grouting (concurrent with excavation) and later secondary grouting.
As the outline Construction Specifications Volume 6, Clause 9.8.3(C), Proprietary
grouts may be used, subject to the Employers Representatives consent. Therefore,
the thixotopical-gel type which consist of liquid A and liquid B was proposed for
Primary Grout.
The thixotopical-gel grouting was famous using in worldwide. The best benefit of
thixotopical-gel grouting is quick setting time. Comparison between thixotopical-gel
grout and single fluid grout with high water cement ratio, the thixotopical-gel grout
was more quicker setting time and best for protect road surface and building area.
Therefore ITD proposed the thixotopical-gel grouting for the MRT Blue Line
Extension Project.
The secondary grouting shall consist of cement liquid part A from the primary
grouting material which is prepared on ground surface batching plant and then
transported to tunnel.
2.
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Method Statement for Primary and Secondary Grouting Doc No. ITD/BE1/MS/T007, Rev.
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(Hold Point)
Signify an important inspection point. This is used for special tests or inspections
which shall be witnessed, signed and dated by the authorized inspector and/or the
Employer and/or the Employers Representative.
W
(Witness Point)
(Witness Point-Optional)
(Surveillance Point)
(Sub-contractor Inspection)
ITPs for sub-contract works shall contain the nominated inspection points and
inspectors.
D
(Documentation Required)
Signify that a test report, material certificate or the like shall be supplied, or that
the particular inspection activity must be verified by a document signed and dated.
It may be in the form of a QA traveler document attached to, or moving through the
process with the products.
R
(Review Point)
Review and verify of quality system documentation and final quality records. This
may vary from a spot review to a full quality audit and may include verification by
ITD that a final report or manufacturers data report has been compiled and is a
complete and accurate record. ITPs shall be reviewed by ITD and at the same time
marked up to indicate ITDs surveillance inspection activities. As previously stated,
all ITPs shall be reviewed and approved by responsible Manager(s) prior to the
commencement of manufacture or construction.
3. Specifications and Reference Documents
Related specification contained in OCS Volume 6 Section 9.8.1 - 9.8.12.
4.
Working Procedures
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Method Statement for Primary and Secondary Grouting Doc No. ITD/BE1/MS/T007, Rev.
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4.1
General
This Section provides the information for performing the primary
grouting with the Thixotopical - gel type grout material
The major activities in primary grouting are:
a) Grout Material Quality Control.
b) Grouting, the grout pressure is measured, monitored and
recorded by the tunnel driving monitoring system on the TBM
working platform number 2 and record with print out by ENZAN
software.
c) Tunnel Segment Movement Monitoring, we have two surrey teams
both on ground and in the tunnel to monitoring ground
displacement and segment deformation by check TBM clearance
to segment for diameter result.
The details for each activity are described in following sections.
4.1.2
Grout Mix
The proposed grout mix is shown in Table 1.
Material
Design Quantity
(per 1 m3 mixed grout)
Liquid A
Cement
240 kg
Bentonite
30 kg
Water
830 kg
Stabiliser
2.4 kg
80 litre
Liquid B
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Method Statement for Primary and Secondary Grouting Doc No. ITD/BE1/MS/T007, Rev.
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This final mix design is subject to laboratory test before actual carried out.
4.1.2.2 Instrument and Equipment to be used
The following instruments and equipment shall be used for
the primary grouting mixing and quality control:
4.1.2.3
ii
iii
Beaker (3 litter).
iv
Stop Watch.
vi
vii
viii
Weight Meter.
b)
Italian-Thai Development PCL.
35
ii
iii
iv
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Method Statement for Primary and Secondary Grouting Doc No. ITD/BE1/MS/T007, Rev.
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c)
d)
ii
ii
e)
Operate the pump and set the flow for the feed
After flow volume stable, take a sample for one
minute.
Conduct the test for three time, compare the
volume which the deviation of volume shall be in
the range (+ -) 3%.
f)
ii
iii
iv
Grout Pressure.
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Method Statement for Primary and Secondary Grouting Doc No. ITD/BE1/MS/T007, Rev.
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Testing Frequency
The frequency of the quality test of the grout material is
shown in Table 3. A summary report shall be submitted
upon the test result of the first 30 rings.
Frequency
First 30 rings
Every ring
4.1.2.5
Table 4: Testing Item and the Acceptance Criteria for Each Test
Item
Specification
Test Method
Test Standard
Specific Gravity
Mud Balance
ASTM D 4380-84
(Reapproved
2001)
Liquid A
Bleeding
Bleeding Test
ASTM C940-98A
Liquid A
Consistency
< 11 seconds
Flow Test
ASTM C939-02
Gel Time
4-12 seconds
Mix Test
N/A
1 Hour
0.03 N/mm 2
ASTM C109M-02
Frequency
Every Shift
Remark
Liquid A
Liquid A+B
Compressive
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Strength
24 Hours
0.4 N/mm 2
first 30 rings
7 Days
0.8 N/mm 2
Every 5 rings
28 Days
1.5 N/mm 2
During
maindrive
4.1.2.6
Mixed
Grout
Deterioration test
In order to ensure that the pot life of liquid A, a
deterioration test shall be performed. All testing as shown
in Table 4 shall be performed both immediately and also
24 hours after mixing Liquid A.
If the test results are within the specified tolerance as per
Table 4, then Liquid A shall be judged to have had no
deterioration.
4.1.3
Grouting
The injection of the grout material shall be performed as the method
statement for tunnel excavation specifies.
The grout pressure and the volume shall be monitored and recorded
by the tunnel driving monitoring system.
The filling rate against the theoretical cavity volume shall be
calculated and recorded by the tunnel driving monitoring system.
4.2
Introduction
Secondary grouting will be completed in correlation with deformation
measurement within 10 day after ring completion and not move than
30 meters behind the TBM face. Secondary grouting shall be at a
pressure not greater than 4 bars, consistent with completely filling all
voids.
The mix design are tabulated as below:
Materials
Proportion
Cement
500 kg
Water
850 litre
Bentonite
50 kg
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Method Statement for Primary and Secondary Grouting Doc No. ITD/BE1/MS/T007, Rev.
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Specification
Test Method
Test Standard
Specific Gravity
Mud Balance
ASTM D 4380-84
(Reapproved
2001)
Bleeding
Bleeding Test
ASTM C940-98A
Consistency
N/A
Flow Test
ASTM C939-02
Compressive
Strength Test
1.5 N/mm 2
at 49 days
4.2.4
ASTM C109M-02
Frequency
Remark
Liquid A
Every internal
5 No rings
Liquid A
Random check
Liquid A
Liquid A
Deterioration test
In order to ensure that the pot life of liquid A, deterioration test shall be
performed. All testing as shown in Table 5 of specified requirement
shall be performed both immediately and also 24 hours after mixing
Liquid A.
If the test results are within the specified tolerance as per the above
Table 5, then Liquid A shall be judged to have had no deterioration.
4.2.5
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Method Statement for Primary and Secondary Grouting Doc No. ITD/BE1/MS/T007, Rev.
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4.2.6
Carry out the grouting until the pressure achieved 3.0-3.5 kg/cm 2.
(Automatic shut down of pump pressure of 3.0-3.5 kg/cm 2).
Change injection point once the grout pressure has achieved 3.03.5 kg/cm2 and leave the grout injection pipe in the hole until the
grout has set. The grout hole plug shall be replaced and fully
tightened once the grout pipe has been removed.
Use new injection pipe for installation into the next grouting
position.
Facilities to be prepared
a
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4.2.7
Injection pipe with ball valve 2 inch dia. same threading with the
grout hole in segment.
Quality Control
Following items as the quality control checklist shall be checked and
monitored during the works.
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Method Statement for Primary and Secondary Grouting Doc No. ITD/BE1/MS/T007,
Rev. C
Inspection Responsibilities
No.
Main Activity
Relevant
Specification
Acceptance Criteria
Document
ITD
Frequency of Inspection/Test
Verification/Acceptance
sign off by
Form Checklist
Subcontractor
Vendor
Site
Engineer
QC
Every Day
N/A
W/O
Every Day
N/A
W/O
Every Day
N/A
Every Day
N/A
ER
No.
Rev.
W/O
MS/T007/1
Site Engineer
W/O
MS/T007/2
Site Engineer
W/O
W/O
MS/T007/3
Site Engineer
W/O
W/O
MS/T007/3
Site Engineer
Primary Grouting
OCS Volume 6
Section 9.8
OCS Volume 6
Section 9.8
Secondary Grouting
OCS Volume 6
Section 9.8
OCS Volume 6
Section 9.8
ASTM D 4380-84
(Reapproved 2001),
ASTM C940-98A
ASTM C939-02
ASTM C109-02
ASTM D 4380-84
(Reapproved 2001),
ASTM C940-98A
ASTM C939-02
ASTM C109-02
ASTM D 4380-84
(Reapproved 2001),
ASTM C940-98A
ASTM C939-02
ASTM C109-02
ASTM D 4380-84
(Reapproved 2001),
ASTM C940-98A
ASTM C939-02
ASTM C109-02
1 July 2013
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Method Statement for Primary and Secondary Grouting Doc No. ITD/BE1/MS/T007, Rev. C
Witness Point
Subcontract Inspection
Witness Point-Optional
W/O
1 July 2013
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R
N/A
Review Point
Not Applicable
Section
Method Statement for Primary and Secondary Grouting Doc No. ITD/BE1/MS/T007, Rev.
No
Test ltem
Specification
Specific Gravity
Set ting
Consistency
Gel time
Tunnel : WB / EB
Test Result
Ring No________
Judgment
Test Standard
Remark
Yes / No
ASTM D 4380-84
(Reapproved 2001),
Liquid A
Yes / No
ASTM C 940-98A
Liquid A
Yes / No
ASTM C939 62
Liquid A
Yes / No
N/A
Liquid (A+B)
1.20
0.02g/cm 3
0-5% (After
1 hour)
< 11
seconds
4 ~ 12
seconds
1 hour
1.
2.
3.
Avg.
0.03 N/mm 2
Yes / No
0.4 N/mm 2
Yes / No
0.8 N/mm 2
Yes / No
1.5 N/mm. 2
Yes / No
See note
1.
24 hour
Mixing Date:
2.
3.
Avg.
ASTM C109-62
See note
7 days
1.
2.
3.
Avg.
28 days
1.
2.
3.
Avg.
Agreed by QC
Name :___________________
(
Date : _____________________
ER
Name :___________________
)
Engineer
See note
)
Engineer
Witnessed Point-Optional by :
__________
(
)
Date : _____________________
Date : ___________________________
July 2013
Page 13 of
Section
Rev. C
Method Statement for Primary and Secondary Grouting Doc No. ITD/BE1/MS/T007,
Note: 1 Div. = (Div. x 2.3942 + 0.9710) x 9.81 N; Calibrated Date May 23, 2013.
1 July 2013
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Method Statement for Primary and Secondary Grouting Doc No. ITD/BE1/MS/T007, Rev.
C
Completed by Site Engineer
Agreed by QC
Name :__________________________________
ER
Name :_______________________________
)
Engineer
)
Engineer
Date : __________________________________
Date : _______________________________
Date : _____________________________________
Date: .
Grouting Time
Ring
No.
Ring No.
Time Finished
Start
Finished
Inspector:
Position of
Injection hole
Grouting Pressure
(2-3.5 kgf/cm 2)
1
1 July 2013
Visual Observation
hole Position
6
Taking Sample
Remark
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Section
Method Statement for Primary and Secondary Grouting Doc No. ITD/BE1/MS/T007, Rev.
Time:
Tunnel : WB / EB
No
Test ltem
Specification
Specific Gravity
Set ting
Consistency
Test Result
Ring No________
Judgment
Test Standard
Remark
Yes / No
ASTM D 4380-84
(Reapproved 2001),
Liquid A
Yes / No
ASTM C 940-98 A
Liquid A
Yes / No
ASTM C939 02
Liquid A
1.35
0.02g/cm 3
0-5% (After
1 hour)
< 15
seconds
1 hour
1.
2.
3.
Avg.
Yes / No
Yes / No
2.
3.
Avg.
35 days
1.
2.
ASTM C 109-02
3.
Avg.
Yes / No
Yes / No
1.5 N/mm. 2
Yes / No
1.
42 days
24 hour
1.
2.
3.
Avg.
49 days
1.
2.
3.
Avg.
Agreed by QC
1 July 2013
See note
ER
Page 16 of
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Method Statement for Primary and Secondary Grouting Doc No. ITD/BE1/MS/T007, Rev.
A
Name :___________________
(
Name :___________________
)
Engineer
Date : _____________________
)
Engineer
Witnessed Point-Optional by :
__________
(
)
Date : _____________________
Date : ___________________________
Note: 1 Div. = (Div. x 2.3942 + 0.9710) x 9.81 N Calibrated Date May 23, 2013.
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Method Statement for Primary and Secondary Grouting Doc No. ITD/BE1/MS/T007, Rev.
Date: .
Inspector:
No.
Ring No.
Max Pressure
Grout Volume
Start Time
Finish Time
Remarks
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
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Section
C
Method Statement for Primary and Secondary Grouting Doc No. ITD/BE1/MS/T007, Rev.
Agreed by QC
Name :_______________________________
Witnessed Point-Optional b
)
Engineer
Date : __________________________________
)
Engineer
Date : _______________________________
Date : _________________
Attachment A
Grouting Material for shield Tunneling Work: Proposal
for Mix Design and Testing Method
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Method Statement for Primary and Secondary Grouting Doc No. ITD/BE1/MS/T007, Rev.
1.
Introduction
This document was prepared to present the design approach and the testing
method of the grouting material that will be used for shield tunneling Hua lamphong
- Sanam Chai Section In order to secure the maximum effect of filling in the void
between the excavated profile and the permanent linings to the underground
works, thyrotrophic -gel grouting material is proposed. A thyrotrophic-gel grouting
material provides enough strength against the ground pressure and the recovery of
fluidity of the grouting material within one hour after grouting this ensuring a
continuous and impermeable void filling. The required properties of thyrotrophic
-gel grouting material are:
1.1
1.2
1.3
1.4
1.5
Specification
Following are the specifications of properties of the thyrotrophic-gel grouting
material for Tunnel Works to secure the maximum effects.
2.1
2.2
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12.3
2.4
Compressive Strength
The designed compressive strength is shown as below:
Table-1 Required compressive Strength
2.5
Curing Time
Compressive Strength
0.03 N/mm 2
0.4 N/mm 2
0.8 N/mm 2
1.5 N/mm 2
3.
Material
Liquid A
Cement
240 kg
Bentonite
30 kg
Water
830 liter
Stabiliser
2.4 kg
80 liter
Liquid B
This final mix design is subject to laboratory test before actual carried out.
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4.
Testing Method
Trial mixing and the grouting mix tests for the grouting material to be used for
Tunnel Works are carried out as follows.
4.1
4.1.2
4.2
Equipment
4.1.1.1
Electric Balance.
4.1.1.2
Hand Mixer.
4.1.1.3
Bucket of 20 litre.
Procedure
4.1.2.1
4.1.2.2
4.1.2.3
4.1.2.4
4.1.2.5
4.2.1.2
Hand Mixer.
4.2.1.3
Bucket of 20 liter.
4.2.1.4
Stop watch.
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4.2.2
Procedure
4.2.2.1
4.2.2.2
4.2.2.3
4.2.2.4
4.3
Measurement of Consistency
4.3.1 Equipment
4.3.2
4.4
4.3.1.1
Bucket of 20 litre.
4.3.1.2
Hand Mixer.
4.3.1.3
4.3.1.4
Stop watch.
Procedure
4.3.2.1
4.3.2.2
4.3.2.3
4.4.1.2
Stop watch.
4.4.2 Procedure
Italian-Thai Development PCL.
35
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4.5
4.4.2.1
4.4.2.2
4.4.2.3
4.5.2
4.5.1.1
4.5.1.2
4.5.1.3
4.5.1.4
Electronic balance.
Procedure
4.5.2.1
4.5.2.2
4.5.2.3
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Measurement of Bleeding
Measurement of Consistency
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Method Statement for Primary and Secondary Grouting Doc No. ITD/BE1/MS/T007, Rev.
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Attachment B
The Laboratory Test Program for Primary and Secondary
Grouting Works
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Method Statement for Primary and Secondary Grouting Doc No. ITD/BE1/MS/T007, Rev.
Item
Specification
Test Method
Date
Specific Gravity
1.200.02 g/cm 3
Mud Balance
12 June 2012
Bleeding
0.5% (1 hour
after Liquid
A mixing)
Bleeding Test
12 June 2012
Consistency
< 11 seconds
Flow Test
12 June 2012
Gel Time
4.12 seconds
Mix Test
12 June 2012
Compressive
12 June 2012
Compressive
Strength
1 Hour
0.03 N/mm 2
24 Hours
0.4 N/mm 2
7 Days
0.8 N/mm 2
28 Days
1.5 N/mm 2
Strength Test
Place
At the institute
which be inform
and submit at
least 1 month
before test date.
At the institute
which be inform
and submit at
least 1 month
before test date.
At the institute
which be inform
and submit at
least 1 month
before test date.
The Laboratory test Program for Primary and Secondary Grouting Works.
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Remark
Liquid A
Liquid A
Liquid A
Liquid A+B
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Method Statement for Primary and Secondary Grouting Doc No. ITD/BE1/MS/T007, Rev.
C
Attachment C
ASTM C939-02 Standard Test Method for PreplacedAggregate Concrete (Flow Cone Method)
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Attachment D
ASTM D4830-84 (Reapproved 2001) Standard Test
Method for Density of Bentonitic Slurries
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