Ms primary grouting revise c

The Kingdom of Thailand
Ministry of Transport
MASS RAPID TRANSIT AUTHORITY OF THAILAND
MRT BLUE LINE EXTENSION PROJECT
CONTRACT 1: UNDERGROUND CIVIL WORKS
(HUA LAMPHONG – SANAM CHAI SECTION)
PREPARED BY:
ITALIAN-THAI DEVELOPMENT PUBLIC COMPANY LIMITED
METHOD STATEMENT
FOR
PRIMARY AND SECONDARY GROUTING
Document No. ITD/BE1/MS/T007, Rev. C
JULY 2013

MRT Blue Line Extension Project Contract 1: Underground Civil
Works
Hua Lamphong – Sanam Chai
Section
Method Statement for Primary and Secondary Grouting Doc No. ITD/BE1/MS/T007, Rev.
C
Document Title: Method Statement for Primary and Secondary Grouting
Document No: ITD/BE1/MS/T007
Document Amendment Record
Revision Date Amendment Record
A 15 February 2012 First submission for approval
B 11 April 2012
Amend as per CSCBL’s Letter Ref. CSCBL/C1/ITD/MST/0678,
Dated 14th
March 2012
C 1 July 2013
Improving some point of this method statement for making it
correct, practical and perfect: in item 4.1.2.3 page 6, 7 and item
4.2 page 9 and in checklist page 13, 15
Controlled Distribution List
Copy
No
Distribution
List
Type of
Issue
Recipient
Copy
No
Distribution
List
Type of
Issue
Recipient
1 MRTA B
2 PMC B
3 CSC B
Type of Issue
“A” For Internal Review& Comment “C” For Acknowledgement or Information or Reference.
“B” For ER’s Approval “D” For Use or Implementation or Construction
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.
Italian-Thai Development PCL. 1 July 2013 Page 2 of
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Table of Contents
1. Scope……………........................................................................................................3
2. Definitions and Abbreviations.....................................................................................3
3. Specifications and Reference
Documents..................................................................4
4. Working Procedures………………………...................................................................4
5. Inspection and Test Plan ……………………….........................................................12
6. Quality Control Checklist for Primary and Secondary
Grouting….............................13
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. Attachment C ASTM C939-02 Standard Test Method for Preplaced-Aggregate
Concrete (Flow Cone Method)……………………………………………………………29
10. Attachment D ASTM D4830-84 (Reapproved 2001) Standard Test Method for
Density of Bentonitic Slurries………………………………………………..……………33
35
Prepared by: __________________________
(Nopporn Rattanchayabun)
Section Manager (TBM Tunnel)
Date : ______________________
Reviewed by: _____________________________
(Prakin Arunotong)
Engineering and Project Control Manager
Date : ______________________
Approved by: _____________________________
(Pairach Supavivat)
Project Director
Date : ______________________
Reviewed by: _____________________________
(Thavesak Rungpiriyadech)
Tunnelling Works Manager
Date : ______________________

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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 Lamphong-
Sanam 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 Employer’s Representative’s 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. Definitions and Abbreviations
Inspection and Testing Plan (ITP) is a document made by ITD or manufacturer or
subcontractor to describe the minimum requirements of the quality control
activities, inspection and test items during fabrication, installation and/or
construction phase, reference documents, required acceptance criteria, certifying
or verifying documents, and inspection parties involved, its all for assure that the
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work or product will be built in accordance with the project specification. Relevant
inspection levels contained in ITP is defined as follows:
H = (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 Employer’s Representative.
W = (Witness Point)
Signify an important inspection point to be witnessed by the authorized inspector.
W/O = (Witness Point-Optional)
Signify an inspection point to be witnessed or optional point not to be witnessed by
the authorized inspector and/or Employer and/or the Employer’s Representative.
S = (Surveillance Point)
Signify an inspection point which may be carried out on a random basis.
Notification of these points are normally not specified (ITD will review the
frequency of inspection results).
X = (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 manufacturer’s 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 ITD’s 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.
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4. Working Procedures
4.1 Primary Grouting Method
4.1.1 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 Material Mixing and Quality Control
In order to ensure that the proposed quality of the thixotropical-gel
type grout material is achieved the quality testing procedure shall be
applied.
Although the testing methods for quality control are described in the
Grouting Material for Shield Tunneling Work: Proposal of Mix Design
and Testing Method, the details method shall be referred to as
follows:
4.1.2.1 Grout Mix
The proposed grout mix is shown in Table 1.
Table 1: Grout Mix for Primary Grout
Solution Material
Design Quantity
(per 1 m3 mixed grout)
Liquid A Cement 240 kg
Bentonite 30 kg
Water 830 kg
Stabiliser 2.4 kg
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Liquid B Special Sodium Silicate 80 litre
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:
i Unconfined compression apparatus.
ii Graduated cylinder (1 litter).
iii Beaker (3 litter).
iv Stop Watch.
v Specimen Mould (5 cm cube).
vi 50 cm cubic case for water measuring.
vii Grout Mixing Plant and Associated Equipment.
viii Weight Meter.
4.1.2.3 Calibration on weight scales of grout mixing plant and check
density of stabilizer and sodium silicate
In order to ensure that the accuracy of weight material
components, mixing ratio, injection flow rate and injection
pressure, the following calibration activities will be
performed every 4 months.
a) Calibration on weight scales of grout mixing plant
i. Remove any object from the top of mixer and make
no load on the mixer.
ii Confirm that 0 kg (No load) on the mixer.
iii Put each weight (20kg) on the mixer and add each
weight until 1300 kg (weight 20 kg = 65
block):record the weight displays each step.
iv Then, lift each weight down from the mixer and
record the weight display each step until weight
display is 0 kg.
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v Repeat process item (I. to IV.) again.
 Total weight shall be measured to an accuracy of
(+ -) 1%.
b) Check specific gravity of stabilizer.
i Pour stabilizer 500 cc. in the beaker.
ii Use specific gravity meter to measure and record
the specific gravity of stabilizer 3 times, then
average the value.
 The specific gravity of stabilizer shall be
measured in the range 1.095 to 1.115 g/cm3
.
c) Check specific gravity of sodium silicate.
i Pour sodium silicate 500 cc. in the beaker.
ii Use specific gravity meter to measure and record
the specific gravity of sodium silicate 3 times, then
average the value.
 The specific gravity of sodium silicate shall be
measured in the range 1.394 to 1.422 g/cm3
.
d) Check stabilizer pump feed test.
i Operate the pump and set the flow for the feed
line.
ii After flow volume stable, take a sample for one
minute.
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 Conduct the test for three time, compare the
volume which the deviation of volume shall be in
the range (+ -) 3%.
e) Grout liquid flow rate.
To ensure an accurate mixing rate at the injection
point, each flow rate of liquid A and B shall be checked
the flow rate at the injection point.
i Prepare a container to pour grout liquid near an
injection point.
ii Start pumping liquid A into a container. Calculate
the flow rate of liquid A upon the time for pumping
and the actual volume of the liquid A shall be in the
range (+-) 3%.
iii Repeat the same procedure above for liquid B.
iv Confirm that the flow rate ratio shall be 11.5 (Liquid
A): 1 (Liquid B).
f) Grout Pressure.
To ensure an accurate of grout pressure gauge, the
pressure gauge should be calibrated and has the
calibration certificate by an external and independent
party.
4.1.2.4 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.
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Table 3 The Frequency of the Quality Test of the Grout Material
Period Frequency
First 30 rings Every ring
After 30 rings in Initial Drive and in whole Main Drive Every 5 rings at Batching Plant (on ground)
4.1.2.5 Quality Testing Items
The following tests shall be performed in accordance with
the testing frequency as specified in Table 3. Table 4
shows the testing items and the acceptance criteria for
each test.
Table 4: Testing Item and the Acceptance Criteria for Each Test
4.1.2.6 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.
35
Item Specification Test Method Test Standard Frequency Remark
Specific Gravity 1.20 + 0.02 g/cm3
Mud Balance
ASTM D 4380-84
(Reapproved
2001)
Liquid A
Bleeding
0-5% (1 hour after
Liquid A mixing)
Bleeding Test ASTM C940-98A
Every Shift
Liquid A
Consistency < 11 seconds Flow Test ASTM C939-02 Liquid A
Gel Time 4-12 seconds Mix Test N/A Liquid A+B
Compressive
1 Hour 0.03 N/mm2
ASTM C109M-02 Every Ring for
Mixed
GroutStrength
24 Hours 0.4 N/mm2
first 30 rings
7 Days 0.8 N/mm2
Every 5 rings
28 Days 1.5 N/mm2 During
maindrive

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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 Secondary Grouting Method
4.2.1 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:
4.2.2 Testing Frequency
The frequencies of the quality test of the grout material are random
checking by 1 sample per time of grouting in tunnel.
4.2.3 Quality Testing Items
The following tests shall be performed in accordance with the testing
frequency. Table of specified requirements shows the testing items
and the acceptance criteria for each test.
35
Materials Proportion
Cement 500 kg
Water 850 litre
Bentonite 50 kg

Works
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Table 5: Specified Requirements of Secondary Grouting Material.
Item Specification Test Method Test Standard Frequency Remark
Specific Gravity 1.35 + 0.02 g/cm3
Mud Balance
ASTM D 4380-84
(Reapproved
2001)
Liquid A
Bleeding
0-5% (1 hour after
Liquid A mixing)
Bleeding Test ASTM C940-98A
Every internal
5 No rings
Liquid A
Consistency N/A Flow Test ASTM C939-02 Liquid A
Compressive
Strength Test
1.5 N/mm2
at 49 days
ASTM C109M-02 Random check Liquid A
4.2.4 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 Work Sequence for secondary grout
The injection of the grout material shall be performed after primary
grouting completed. During each shift secondary grouting shall be
performed at the back up on the working stage of TBM. The
secondary grouting shall use the mobile pump order to control the
pressure to 3.5 kg/cm2
. The position of grouting shall be located at
existing drill holes at every interval of 5 No rings with wet hole. Any
grout holes showing evidence of water leakage shall also be
secondary grouted, as will those nearest to any wet joints. However,
the most important issue to concern is the surface displacement which
should be considered together between the surface monitoring
instrument result and the tunnel driving monitoring system. If one
both systems can detect the settlement or heave, engineer have to
stop secondary grouting at that point and re-consider grout pressure
before processing the secondary grout.
The procedure for injection of the secondary grout shall be as follows:
a Open grout hole plug.
Each segment grout hole plug shall be carefully removed in order
to prevent any inflow of ground water or soil through the hole.
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b Drill hole through the non-return valve in segment grout hole
(never key segment). The 28 mm electric drill (400 mm. length)
shall be inserted into the position of the abandoned non-return
valve.
c Installation of injection pipe at grout hole.
The injection pipe shall be installed as soon as possible after
removing grout hole plug.
d Connect grout hose to injection pipe.
e Carry out the grouting until the pressure achieved 3.0-3.5 kg/cm2
.
(Automatic shut down of pump pressure of 3.0-3.5 kg/cm2
).
f Grouting volume shall be measured by measurement liquid
volume using in mixing tank.
g Change injection point once the grout pressure has achieved 3.0-
3.5 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.
h The compressive strength test specification is required grout
strength 1.5 N/mm2
. @ 49 days.
i Use new injection pipe for installation into the next grouting
position.
j Change grouting hose to next position and continue.
4.2.6 Facilities to be prepared
a Grouting pump with pressure limiter.
b Electric Hand Drill whole size 28 mm. x 400 mm. length
c Tank of agitator installed in TBM back up unit.
d Injection pipe with ball valve 2 inch dia. same threading with the
grout hole in segment.
e Grout hose, size 1½ inch.
4.2.7 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
Italian-Thai Development PCL. 1 July 2013 Page 12 of 35
PROJECT : MRT Blue Line Extension
Contract : Underground Civil Work
(Hua Lamphong – Sanam Chai Section)
Location/Area : Tunnel at Hua Lamphong to Sanam Chai Station
INSPECTION AND TEST PLAN
For : Method Statement Primary and Secondary Grouting
Quality System : ISO 9001
Document Type : Controlled
No. Main Activity Relevant
Specification
Acceptance Criteria Frequency of Inspection/Test
Inspection Responsibilities Document
Subcontractor Vendor
ITD
ER
Form Checklist
Verification/Acceptance
sign off by
Site
Engineer
QC No. Rev.
A Primary Grouting
1
Primary Grout Material
Test
OCS Volume 6
Section 9.8
ASTM D 4380-84
(Reapproved 2001),
ASTM C940-98A
ASTM C939-02
ASTM C109-02
Every Day X N/A W/O R W/O MS/T007/1 C Site Engineer
2
Primary Grouting Shift
Report
OCS Volume 6
Section 9.8
ASTM D 4380-84
(Reapproved 2001),
ASTM C940-98A
ASTM C939-02
ASTM C109-02
B Secondary Grouting
1
Secondary Grout Material
Test
OCS Volume 6
Section 9.8
ASTM D 4380-84
(Reapproved 2001),
ASTM C940-98A
ASTM C939-02
ASTM C109-02
2
Secondary Grouting Shift
Report
OCS Volume 6
Section 9.8
ASTM D 4380-84
(Reapproved 2001),
ASTM C940-98A
ASTM C939-02
ASTM C109-02
H Mandatory Hold Point Until Approved S Surveillance Point – Random ITP/Each Quantity R Review Point
W Witness Point X Subcontract Inspection N/A Not Applicable
W/O Witness Point-Optional D Document or Record Required

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Primary Grout Material Test
(Form No. MS/T007/1, Rev. C)
Mixing Date: Time: Tunnel : WB / EB Ring No________
No Test ltem Specification Test Result Judgment Test Standard Remark
1 Specific Gravity
1.20
±0.02g/cm3 Yes / No
ASTM D 4380-84
(Reapproved 2001),
Liquid A
2 Set ting
0-5% (After
1 hour)
Yes / No ASTM C 940-98A Liquid A
3 Consistency
< 11
seconds
Yes / No ASTM C939 – 62 Liquid A
4 Gel time
4 ~ 12
seconds
Yes / No N/A Liquid (A+B)
5
CompressiveStrengthTest
1hour
1.
ASTM C109-62
2.
3.
Avg. 0.03 N/mm2
Yes / No See note
24hour
1.
2.
3.
Avg. 0.4 N/mm2
Yes / No See note
7days
1.
2.
3.
Avg. 0.8 N/mm2
Yes / No
28days
1.
2.
3.
Avg. 1.5 N/mm.2
Yes / No See note
Note: 1 Div. = (Div. x 2.3942 + 0.9710) x 9.81 N; Calibrated Date May 23, 2013.
Italian-Thai Development PCL. July 2013 Page 13 of
35
Completed by Site Engineer Agreed by QC ER
Name :___________________
( )
Engineer
Date : _____________________
Name :___________________
( )
Engineer
Date : _____________________
Witnessed Point-Optional by :
__________
(
)
Date : ___________________________

Works
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Primary Grouting Shift Report
35
Name :__________________________________
(
)
Engineer
Date : __________________________________
Name :_______________________________
(
)
Engineer
Date : _______________________________
Witnessed Point-Optional by : __________________
(
)
Date : _____________________________________
Location: West Bound / East Bound Date: …………………………………………. Day Shift / Night Shift Inspector: ………………
Ring
No.
Previous Ring Excavation Grouting Time
Grouting Pressure
(2-3.5 kgf/cm2
)
Position of
Injection hole
Visual Observation
hole Position
Taking Sample Remark
Ring No. Time Finished Start Finished 1 2 3 4 5 6 7 1 2 3 4 5 6 7

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Secondary Grout Material Test
Mixing Date: Time: Tunnel : WB / EB Ring No________
No Test ltem Specification Test Result Judgment Test Standard Remark
1 Specific Gravity
1.35
±0.02g/cm3 Yes / No
ASTM D 4380-84
(Reapproved 2001),
Liquid A
2 Set ting
0-5% (After
1 hour)
Yes / No ASTM C 940-98 A Liquid A
3 Consistency
< 15
seconds
Yes / No ASTM C939 – 02 Liquid A
4
CompressiveStrengthTest
1hour
1.
ASTM C 109-02
2.
3.
Avg. -
Yes / No
24hour
1.
2.
3.
Avg. -
Yes / No
35days
1.
2.
3.
Avg. -
Yes / No
42days
1.
2.
3.
Avg. -
Yes / No
49days
1.
2.
3.
Avg. 1.5 N/mm.2
Yes / No See note
35
Name :___________________
( )
Engineer
Date : _____________________
Name :___________________
( )
Engineer
Date : _____________________
Witnessed Point-Optional by :
__________
(
)
Date : ___________________________

MRT Blue Line Extension Project Contract 1: Underground Civil Works
Section
A
Note: 1 Div. = (Div. x 2.3942 + 0.9710) x 9.81 N Calibrated Date May 23, 2013.
35

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Secondary Grouting Shift Report
Italian-Thai Development PCL. 1 July 2013 Page 16 of 35
Location: West Bound / East Bound Date: …………………………………………. Day Shift / Night Shift Inspector: ………………
No. Ring No. Grout Hole 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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Attachment A
Grouting Material for shield Tunneling Work: Proposal
for Mix Design and Testing Method
35
Completed by Site Engineer Agreed by QC E
Name :__________________________________
(
)
Engineer
Date : __________________________________
Name :_______________________________
(
)
Engineer
Date : _______________________________
Witnessed Point-Optional b
(
)
Date : _________________

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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 Non shrinkage after grouting void.
1.2 High resistance to underground water before setting.
1.3 High controllability of grout flow.
1.4 Suitability for along distance pumping.
1.5 No separation of solid material from solution during storing and
pumping.
2 Specification
Following are the specifications of properties of the thyrotrophic-gel grouting
material for Tunnel Works to secure the maximum effects.
2.1 Gel (Setting) Time of Liquid A and Liquid B
Gel Time is specified between 4 and 12 seconds
Grouting material will be exposed to ground water during grouting while it
has fluidity. If the gel time is too long, the grouting material will be diluted
and lose the expected properties. Conversely, if the gel time is too short,
the void will not be fully filled because the grouting material can not be
flown from the grouting point to the whole void. The resulting insufficient
grouting cause round settlement and poor water tightness.
From the above points, the most appropriate gel time is specified between 4
and 12 seconds.
2.2 Bleeding Rate of Liquid A
The bleeding rate shall be less than 5% at 1 hour after mixing
Grouting material with high bleeding rate does not have long usable life
because much bleeding cause separation of grouting material and blockage
of Liquid A in the pipeline from the grouting plant to tunneling face.
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12.3 Consistency (Flow Rate) of Liquid A in P-Type Funnel Test
Consistency of Liquid A shall not be greater than 11 seconds If Liquid A has
high consistency, it may cause a blockage. The maximum value of the
consistency of Liquid A in P-Type funnel is specified as 11 second.
2.4 Compressive Strength
The designed compressive strength is shown as below:
Table-1 Required compressive Strength
Curing Time Compressive Strength
Mixing after 1 hour 0.03 N/mm2
Mixing after 1 day 0.4 N/mm2
Mixing after 7 days 0.8 N/mm2
Mixing after 28 days 1.5 N/mm2
2.5 Usable Life of Liquid A
Usable life of Liquid A shall be minimum 24 hours for long distance
pumping from the mixing plant on ground to tunneling face.
3. Proposed Mix Design
The mix proportion of the thyrotrophic-gel grouting material for Tunnel Westbound
and Eastbound is proposed as below.
Table – Mix Design
Solution Material Quantity (per 1 m3
mixed grout)
Liquid A Cement 240 kg
Bentonite 30 kg
Water 830 liter
Stabiliser 2.4 kg
Liquid B Special Sodium Silicate 80 liter
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 Liquid A mixing procedure
We were separated liquid of cavity grouting to 2 parts, one part is Liquid A
component, betonies, stabilizer and water, another part is Liquid B. It is
accelerator. The density of Liquid A will be measured by volume of weight,
actual measured density and theoretical density should be compared.
4.1.1 Equipment
4.1.1.1 Electric Balance.
4.1.1.2 Hand Mixer.
4.1.1.3 Bucket of 20 litre.
4.1.2 Procedure
4.1.2.1 Put water in bucket 20 litre amount according to
design mixed.
4.1.2.2 Put betonies in bucket mix by hand mixing, start
stop watch.
4.1.2.3 At time 1.30 minutes put cement in bucket.
4.1.2.4 At time 2.30 minutes put cement in bucket.
4.1.2.5 Mix grout until 3 minutes stop mixing and used Liquid A in
other testing.
4.2 Measurement of Liquid A bleeding
Due to keep good pump ability of grout, bleeding of grout material is
unavoidable. Bleeding seams a kind of segregation of mixed grout material.
4.2.1 Equipment
4.2.1.1 Mess cylinder 500 ml.
4.2.1.2 Hand Mixer.
4.2.1.3 Bucket of 20 liter.
4.2.1.4 Stop watch.
4.2.2 Procedure
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4.2.2.1 Mixed liquid A in bucket.
4.2.2.2 Put Liquid A in mess cylinder 500 ml.
4.2.2.3 Measure the bled water quantity at one hour later.
4.2.2.4 Bleeding procedure formula is Bleeding percentage = (Bled
water volume (m1.)/500 ml.) *100
Remark
a Limit of Bleeding is defined as 5% and for laboratory
test 2%.
b In air entraining type grout the bleeding is less than
ordinary grout.
4.3 Measurement of Consistency
4.3.1 Equipment
4.3.1.1 Bucket of 20 litre.
4.3.1.2 Hand Mixer.
4.3.1.3 Pre pact flow cone.
4.3.1.4 Stop watch.
4.3.2 Procedure
4.3.2.1 Mixed Liquid A in bucket of 20 litre
4.3.2.2 Fill Liquid A in bucket.
4.3.2.3 Discharge grout, stop watch until the grout was empty
record time by sec.
4.4 Measurement of gel time
Gel time check is related to the performance of accelerator. It is defined by a
time (see) since start mix liquid A and Liquid B until it become harden (no
flow ability). Gel time is measured by “Two cup met hid”.
4.4.1 Equipment
4.4.1.1 Beaker of 2000 cc made of plastic w/side hand 2 pieces.
4.4.1.2 Stop watch.
4.4.2 Procedure
35

Section
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4.4.2.1 Prepare Liquid A (850 cc-950 cc) and Liquid B (50 cc-150
cc) in the beaker.
4.4.2.2 Liquid A pour to Liquid B, start watch and Liquid B pour to
Liquid A repeat this until no flow ability is observed and
measure this time.
4.4.2.3 Record gel time.
4.5 Measurement of Compressive Strength
Test cube (5 cm.* 5 cm.) are normally used for this test, 3 test cube are
tested and water curing method is used.
4.5.1 Equipment
4.5.1.1 Beaker of 200 cc. made of plastic w/side hand 2 pieces.
4.5.1.2 Test piece mould for mortar.
4.5.1.3 Compressive strength machine (small capacity 20 kg. More
or less).
4.5.1.4 Electronic balance.
4.5.2 Procedure
4.5.2.1 Prepare Liquid A and Liquid B same quantity as gel time
check.
4.5.2.2 Liquid A pour to Liquid B and Liquid B to Liquid A repeat 2
time and pour Liquid A+B in test piece mould for mortar
before it hardens.
4.5.2.3 Check compressive strength at time 1 hr, 1 day, 7 days, 28
days.
35

Works
Section
C
Measurement of Bleeding
35

Section
C
Measurement of Consistency
35

Works
Section
C
Measurement of Specific Gravity
35

Works
Section
C
Measurement of Gel Time
35

Section
C
Attachment B
The Laboratory Test Program for Primary and Secondary
Grouting Works
35

Works
Section
C
The Laboratory test Program for Primary and Secondary Grouting Works.
35
Item Specification Test Method Date Place Remark
Specific Gravity 1.20±0.02 g/cm3
Mud Balance 12 June 2012
At the institute
which be inform
and submit at
least 1 month
before test date.
Liquid A
Bleeding
0.5% (1 hour
after Liquid
A mixing)
Bleeding Test 12 June 2012
At the institute
which be inform
and submit at
least 1 month
before test date.
Liquid A
Consistency < 11 seconds Flow Test 12 June 2012 Liquid A
Gel Time 4.12 seconds Mix Test 12 June 2012 Liquid A+B
Compressive
Strength
1 Hour 0.03 N/mm2
Compressive
Strength Test
12 June 2012 At the institute
which be inform
and submit at
least 1 month
before test date.
24 Hours 0.4 N/mm2
7 Days 0.8 N/mm2
28 Days 1.5 N/mm2

Section
C
Attachment C
ASTM C939-02 Standard Test Method for Preplaced-
Aggregate Concrete (Flow Cone Method)
35

Section
C
35

Section
C
Attachment D
ASTM D4830-84 (Reapproved 2001) Standard Test
Method for Density of Bentonitic Slurries
35

Section
C
35

Ms primary grouting revise c

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