Professional Documents
Culture Documents
9.1
GROUT MATERIALS
The modication of soil and rock properties by lling voids and cracks dates
back two centuries. The materials used to ll the voids and cracks are
termed grouts. Grouts run the gamut from low viscosity liquids to thick
mixtures of solids and water. Grouts which consist of a owable mixture of
solids and water are called suspended solids grouts. The most common by far
is Portland cement and its many variations.
Portland cement was invented in 1824. The raw materials used in its
manufacture are limestone, quartz sand, clay and iron ore. These supply the
necessary ingredients lime, silica, alumina, and iron. Properly proportioned
quantities of the raw materials are pulverized and red to result in cement
clinkers. These are nely ground and mixed with up to ve percent gypsum
to make the nished product. Thousands of tons are produced annually in
the USA. A small percentage of this total is used for grouting.
Portland cements are available commercially in many different forms,
including varieties for high early strength and for sulfate resistance and very
nely ground materials called micrones.
9.2
PORTLAND CEMENT
FIGURE 9.2 Water owing from large cracks in a concrete dam face.
(Courtesy of Engineered Solutions, Inc., Davis, CA.)
design and data on industry standard drill rod and casing are given in later
chapters.
The process of sealing crack generally follows in sequence the steps
outlined below:
1.
2.
3.
4.
5.
6.
Injection pressure must be kept below that which would break the seal. Trial
and error procedures may be necessary to determine this limit. On the other
hand, pressure must be high enough so that the pumped volume will empty
the tank before initial set. If grout cannot be pumped at a high enough rate,
pumping pressure may be increased if this is feasible, or the water-cement
ratio may be increased. If the pumped volume decreases while the pumping
pressure increases, this is termed refusal, and pumping must be stopped
when the allowable pressure is reached. If steady ow continues without
pressure increase, either grout is lling ssures well beyond the face (which is
good), or grout is leaking into areas beyond the wall (which is bad).
Reducing the water-cement ratio may help to solve this problem.
Cement grouting is done on a large scale in underground mines.
Virtually all mines taking ore from areas near or under rivers, lakes or the
oceans will have water owing through shafts and tunnels, as well as into the
areas being mined. The steps in sealing seepage into existing mice tunnels are
similar to those described for concrete walls. Methods for sealing water
problems during the construction of tunnels are detailed in the chapter
dealing with tunnels.
Cement grouting is also done on a large scale in shafts. Water
problems and methods of dealing with them are discussed in Chapter 19.
9.3
MICROFINE CEMENTS
Microne cement was developed in Japan, to ll the gap left when the use
of low viscosity chemical grouts was banned following a toxicity incident
in 1970. The product, MC-500, was brought to the United States in the
mid 1970s. It is a very nely ground material, as shown in Figure 9.1, consisting of 75% Portland cement and 25% blast furnace slag. The ne size
of the particles allow penetration into much smaller voids and ssures
than Portland cement can, and also keep the particles in suspension much
longer.
MC-500 can be used with water-cement ratios of one and higher.
Without additives other than a suspension agent the initial setting time is
four to ve hours, at ambient temperatures. Shorter setting times, as low as
several minutes, can be attained by adding sodium silicate, or AC-400 grout.
Viscosity of a mix with a w-c ratio of two is about ten centipoises (cps).
The equipment and procedures for working in the eld with long
setting times is similar to those used with Portland cement. When working
with short setting times, however, specialized equipment is needed (the same
is true for Portland cement). The accelerator cannot be added to the tank
holding the mixed grout, because there wouldnt be enough time to empty
the tank before the grout sets. Grout and accelerator are brought to the
injection point by separate pipes or hoses, and mix as they enter the
formation. Since the proportion of accelerator to grout is critical, the pumps
moving these materials must be capable of very accurate volume control.
Such pumping systems, called metering systems, are described more fully in
Chapter 14.
The rst major project done in the United States with MC-500 was the
Helms Pumped Storage Project near Fresno, CA, in 1982. Here, a
previously unidentied vertical shear zone up to 35 feet wide was
encountered in granitic rock, during construction of power tunnels. About
120 tons of MC-500 were injected at pressures up to 800 psi to seal the
tunnels against leakage.
MC-500 costs up to eight times as much as Portland cement. Its use,
therefore, is restricted to projects where other procedures are not feasible,
either for engineering or economic reasons. These restrictions, however, still
leave a huge market for micrones.
Other microne cements are, of course, available, some with distinctly
different composition and characteristics. One of these is MC-100, the
grading of which is also shown in Figure 9.1. This product is commercially
available as a byproduct of blast furnace slag grinding, and is 100% slag
Thus it is low cost and readily available in large quantities. It cannot be used
by itself due to a very long setting time, and must be activated in the eld
with a strong alkali like sodium hydroxide, after a dispersant and the cement
have been mixed. Another product is MC-300, which is 100% ne ground
Portland cement. MC-300 and MC-100 can be blended in various
proportions to lower the cost of pure cement. If MC-300 is used at more
than 25%, it will activate the MC-100. Characteristics of these products and
mixes and of other micrones, including formulae for mixing, can be found
in manufacturers brochures.
9.4
JET GROUTING
The concept of using high velocity uid jets to cut into soil masses was
developed in Japan in 1965. By the early 1970s jet grouting equipment and
techniques had been developed. The method soon spread to western Europe,
and then to the United States in the early 1980s.
There are three jet grouting systems in common use. These are the
single jet or monouid system, the two uid, and the three uid systems. All
systems require the placement of the jet pipe to the bottom of the depth to
be treated. This is done using conventional drilling methods appropriate for
the soil being treated. Depths of 150 feet have been successfully treated, and
greater depths are possible under certain conditions. Any soil in which the
jet pipe can be placed can be successfully treated. Adverse condition include
soil deposits which contain large amounts of boulders.
In the monouid system, a pump moves the grout at pressures of
6000 psi and more to a set of nozzles located just above the drill bit. The jet
exits the nozzles at speeds up to 600 feet per second, breaking up and mixing
with the soil surrounding the jet rod. The energy of the jet is great enough to
spread grout up to a radial distance of 15 to 20 inches in cohesive soils and
20 to 30 inches in granular deposits. When the jetting action starts, the drill
string is rotated between 10 and 20 rpm, and raised at a rate between 10 and
20 inches per minute. The grout, generally with a w-c ratio between one and
two, may contain bentonite if water tightness is essential. It enters the
formation at rates between 10 and 25 gpm. The result is a relatively uniform
column of soil-cement, with compressive strengths ranging from 250 psi for
organic soils and clays to 1000 psi for sands and gravels.
The radial spread of grout is more a function of the volume of grout
placed per unit volume of soil than it is to the placement pressure. The
volume placed is related to the rotation and lifting rates. While data such as
given above may be used for selecting starting values, the actual values of
all the parameters involved should be determined for major eld jobs by
full scale tests and evaluation. These tests may be incorporated into the
project.
The two uid system uses a jet of air surrounding the grout jet.
Typically, this increases the radius of inuence by several inches.
The three uid system uses a water jet surrounded by an air jet, placed
above but close to the grout jet, to pulverize the soil. The mixture of soil,
water, and air above the grout jet creates an airlift which pushes excess
water and soil nes to the surface, through the annular space between the
drill string and the bore hole. This system gives a larger radius of inuence,
by a half a foot or more, and results in more uniform soil-cement, since the
soil is homogenized by the water-air jet before the grout is injected. The
FIGURE 9.3 (a) Range of soils suitable for jet grouting. (Courtesy of
Nicholson Construction Co., Cuddy, PA.) (b) Jet grouting when vertical
drilling is not feasible. (Courtesy of Nicholson Construction Co., Cuddy, PA.)
9.5
COMPACTION GROUTING
Compaction grouting differs from all other grouting methods in that the
grout mix is specically designed so as not to permeate the soil voids or mix
with the soil. Instead, it displaces the soil into which it is injected. In
granular deposits not at their maximum density, the volume of voids is
reduced and the deposit is locally densied. This provides added supporting
capacity in the locally densied volume. If the soil is already in the dense
state, the major effect is displacement. If the displacement effect reaches an
open face, the face will move away from the displacement source. This effect
can be used to lift and level slabs and footings. If the grout is stronger than
the dense soil it displaces, it will also add supporting capacity locally.
Compaction grout is a very stiff mixture dened in 1980 by the ASCE
Grouting Committee as Grout injected with less than 1 inch slump,
helps resist surface heave. Shallow work is generally done from the top
down, using the initial grout spheres and foundations to prevent surface
heave. Figure 9.5 shows a footing reinforced by compaction grouting.
Compaction grouting is often done to lift and level slabs and
structures, as well as to prevent further settlement. Such work requires
close control of the changing elevations, to prevent damage to the structure.
9.6
FIGURE 9.6
common, as shown in Figure 9.7, but the initial spacing is much less than
that used for consolidation grouting. Grout may be injected at the top of the
hole (the collar), or in selected portions along the length of the hole, by using
isolating devices called packers. These devices are discussed and illustrated
in Chapter 14. The depth of the curtain is determined by the criterion that it
FIGURE 9.7 Location and spacing of grout holes under an earth ll dam.
(Houlsby, A.C., Cement Grouting for Dams, Grouting in Geotechnical
Engineering, New Orleans, LA, p 4, Feb. 1982. Reproduced by permission of
ASCE, Reston, VA.)
must increase the pre-curtain ow path sufciently so that the head loss in
the longer ow path overcomes the tendency toward piping or signicant
volume loss (if the curtain seals the previously critical ow paths, so much
the better).
In earth ll dams, grout curtains placed for preventive purposes are
completed before or during the very early ll stages. For remedial purposes,
curtains can be placed from the crest of the dam, if it isnt too high, or from
the downstream slope.
Figure 9.8 shows a cross-section through a concrete dam. Such dams
are built with galleries that are used for inspection, for drainage of seepage
water, and for grouting. Grout curtains are constructed from within the
lowest gallery, after the concrete has set and cooled.
A grout curtain may be constructed with a single row of holes spaced
closely together, perhaps three to ve feet apart. Using a single row of holes
is reasonable, because the foundation grouting would have lled all the
larger ssures. Therefore, to ll the ner openings the cement grouting
SUMMARY
FIGURE 9.10 Soilcrete arch above tunnel structure. (Billings, T., et al.,
Grouting Program Bridges New Building Loads over Unused Railroad
Tunnel, Foundations and Ground Improvement, Geotechnical SP No. 113,
June 2001, p 126. Reproduced by permission of ASCE, Reston, VA.)
9.8
REFERENCES
Internet
http://www.jet-grouting.com/overview.htm
http://www.trevispa.com/tecnologie consolidamenti e.html
9.9
PROBLEMS
9.1
9.2
9.3
9.4
9.5
9.6
9.7
What are the major differences among the various cements used for
grouting?
Compare jet grouting and deep mixing in regard to advantages of each.
List the ingredients and proportions of a typical compaction grout.
Dene piping, its causes, and cures.
When grouting with normal Portland cement, what rules of thumb are
normally followed for a) allowable pumping pressure, and b)
groutability of a formation?
You are supervising several eld jobs. One of your crew chiefs just
called in. He says he has been pumping Portland cement for several
days and he is now having trouble maintaining reasonable ow rates
without exceeding allowable pumping pressure. What do you tell him?