Professional Documents
Culture Documents
16.1
INTRODUCTION
control may be apparent in the design state. If so, remedial measures can be
integrated into the overall construction process. However, seepage control
procedures are generally carried out after the structure is completed.
Creating a barrier against water ow may be done by grouting specic
individual ow channels or by constructing a grouted cut-off, or grout
curtain through some or all of a pervious formation. If only a limited
number of channels is available for water ow, it is feasible and usually
preferable to use procedures aimed at individual channels. These are
discussed in this chapter. Grout curtains are discussed in the following
chapter.
If many channels are available for water ow, but ow is occurring
only through a few of them, seepage control procedures often result in
shifting the water ow from grouted channels to previously dry channels. If,
in the end, a large number of channels must be grouted, other procedures
will probably be more cost-effective than treating ow channels one at a
time.
If many ow channels are available and owing, such as in the case of
granular soils, or severely ssured rock, procedures are generally used which
attempt to impermeabilize a predetermined volume of the formulation.
These are discussed in Chap. 17.
Typical seepage problems include inltration through ssures in rock,
such as the tunnels in Figs. 16.1 and 16.2, and through joints and porous
zones in concrete, as shown in Fig. 16.3. Figure 16.1 shows a drift (tunnel) in
a copper mine in Canada, 250 ft below ground surface. Many thousands of
feet of such drifts are required even in a small mine to provide access from
the main shafts to the ore bodies. Typically, the drifts will intersect
numerous minor fault zones as well as some major ones. Some of the cracks
and ssures will conduct surface water from rivers, lakes, and precipitation
into the drifts. In Fig. 16.1, individual leaks cannot be seen, but their
aggregate readily shows as several inches of water on the oor. Water from
this and every other wet drift must be collected and pumped out of the mine.
As the ore zones are developed, total seepage increases. Eventually, it
becomes more economical to shut off the seepage than pay continuously
increasing pumping costs.
Figure 16.4 is a geologic map of the 250 level containing Fig. 16.1,
which was taken looking toward point b. Figure 16.5 is an enlarged view of
the zone, showing the cracks and faults as plotted by the mine geologists.
Also shown are a number of grout holes, which were drilled into fault zones
identied on the geologic map. Grouting through these holes proved totally
ineffective in reducing the seepage. Other procedures developed on the basis
of this experience were effective in controlling seepage. See Sec. 16.3.
FIGURE 16.1
Figure 16.2 is a slope entering a coal seam near Pittsburgh. The photo
shows a location several hundred feet downslope. Groundwater entered at
many points, generally as drips and occasionally as a very small steady ow.
Most of the year, the water was of no consequence. In winter, however,
icicles formed as shown, interfering with coal car movement along the tracks
and also making the area hazardous for personnel. It was possible to seal the
leaks completely by chemical grouting.
Figure 16.3 is a vehicular tunnel in Baltimore. Water is shown entering
in small amounts through a construction joint in the concrete. The volume
of water was insignicant, but tiles could not be placed over the wet zone.
Grouting with chemicals successfully stopped the seepage.
FIGURE 16.2
16.3
LABORATORY STUDIES
The reason the coal slope and tunnel jobs were successful, as opposed to the
mine work shown in Fig. 16.1, is that different techniques were used. These
were developed by eld and laboratory research to determine why the
grouting in the copper mine was ineffective. The original eld work dates
back to 1957 and is one of the earliest attempts to apply chemicals (other
than silicates) to mine grouting. This work indicated clearly that the route
grout would follow (from its injection point to its exit point or nal
location) could not be determined with any accuracy by interpretation of the
geologic map coupled with visual site examination. In fact, the complexity
of seepage through a ssured rock mass virtually precludes the effective
preplanning of a grouting operation.
Following the initial mine grouting, a series of laboratory experiments
were set up to simulate eld seepage conditions [2]. Lucite tubing was used
to represent seepage channels and drill holes. In the model shown in Fig.
3
16.6, BCDE is 38 in. ID; AC and FG are 16
in: ID; lines 1, 5, and 6 are 18 in:
1
ID; and the rest are 16 in: ID. ACDE represents a fault zone, and BC
FIGURE 16.3
FIGURE 16.4
FIGURE 16.5
FIGURE 16.6
TABLE 16.1
Pipe No.
cc
cc
1
2
3
4
5
6
7
8
9
10
11
12
13
Total ow
305
43
21
15
395
455
12
78
48
46
35
34
39
1526
20
3
1
1
26
30
1
5
3
3
2
2
3
169
22
8
9
232
210
5
44
32
37
20
7
33
828
20
3
1
1
28
26
1
5
4
4
2
1
4
bearing ssures and cracks. Holes are drilled in the simplest fashion, often
by jackhammer. Dry holes are generally worthless and should be
abandoned. Wet holes (holes that strike water) are generally useful and
are dye-tested as soon as completed.
The dye test is done with the grout plant by pumping dyed water
through a packer placed at the collar of the wet hole just drilled. The dye
concentration must be carefully controlled, as discussed in Sec. 15.5.
Pumping pressures should be kept well below the pump capacity. If these
criteria limit the pumping rate to less than a gallon per minute, it may be
best to abandon the hole and drill a new one. (These criteria apply to work
with low-viscosity grouts. When working with polyurethane, cost-effective
pumping at much lower rates is possible.) The rate noted is approximate and
may well vary from job to job. At some low rate for each specic job it will
become economically more feasible to drill new holes to nd higher takes
rather than to treat tight ones. Job experience will soon dictate which wet
holes need not even be tested.
When the dye test begins, the adjacent wall area is carefully watched
for evidence of dye. When dye is rst seen at any point, the time since the
start of pumping is noted as well as the pumping pressure and rate. Dye tests
may be stopped when dye appears at one point or may be continued until a
number of different locations show dye. (Generally, the points where dye
appears are in areas which are already wet or owing. This is the assumed
condition in the discussion which follows. If dye appears only in areas which
were dry prior to the dye test, the hole should be abandoned.) For each
point, time, pressure, and rate are recorded.
Every time dye appears, this indicates that an open seepage channel
exists between the packer and the point where dye appears. The exact
location of the channel within the rock mass is not known, but if the drill
hole being tested made water, then the established channel must reach into
the water source somewhere. Therefore, the hole is worth grouting.
The time recorded for the appearance of dye is the maximum gel time
that can be used to seal that particular channel. If longer gel times are used,
the grout will run out of the leak before it sets. If the time is short, on the
order of 5 or 10 sec, this may be too short a gel time to handle readily. The
effective time can be lengthened by lowering the pumping rate. This is a
necessary step when attempting to seal a number of zones from one hole and
one of the zones has a very short return time.
If the return time is long, say, 5 min or more, it can be shortened by
increasing the pumping rate. This will generally raise the pumping pressure
and may therefore not be feasible if allowable working pressures would be
exceeded. It is usually not productive to treat holes that show return times of
10 min and more when holes with shorter return times are available.
FIELD WORK
Except for very limited special cases, all of the grouts used must be
permanent. They must have adequate strength and imperveousness, and
these properties must not deteriorate with age or by contact with ground or
groundwater. The grouts must have controllable setting times over a wide
range, be acceptably nonhazardous to humans and ecology, and inexpensive
enough to be competitive with other construction alternatives. Finally, they
must have a low enough viscosity or particle size to permit placement at
acceptable economic rates and safe pressures. Domestically, most seepagecontrol work currently uses the acrylics, with the use of polyurethanes on
the increase, and the use of silicates waning (see also data on microne
cements).
Metering pumps are highly desirable for dealing with seepage
problems for both the dye tests and the actual grouting. (For water-reactive
polyurethanes, single pumps can often be used effectively.) Once a hole has
been drilled and tested and it has been determined that grouting is in order,
the pump suction lines may be switched directly from the dyed water tanks
to the grout tanks. The use of valved quick-couplings at these points saves a
good deal of time. Dye may also be used in the grout, a color different from
that used for dye testing. Proportions of this dye must also be carefully
controlled, so that it is not identiable at 100% dilution.
When pumping begins, the pumping volume should be brought as
quickly as possible to that used during the tests, and the grout itself should
have a gel time of about three-quarters the previously recorded return time.
The pumping pressure is monitored to make sure it does not exceed the
allowable, but otherwise no attempt need be made at this stage to keep the
pressure at dye test values. The leak is watched closely. It should begin to
seal at about the recorded return time. If this does not happen and dye (of
the color used in the grout) does not appear at the leak, then dilution
beyond the ability to gel has occurred. (This would normally mean too high
a dye concentration was used in the dye tests.) If dye does appear but the
leak does not seal, then dilution of the grout has extended the gel time
beyond the return time. This may be counteracted by decreasing the gel time
(easy to do with metering equipment but very difcult with equal volume
FIGURE 16.7
equidistant along the 100 ft length lead directly to these draft tubes and
waterwheels.
Leaks occurring at several points in the three access ways were a
continual annoyance to maintenance and inspection personnel. They were
found mainly along construction joints in the concrete structure and to a
lesser extent in honeycombed areas in the concrete. Water at 358F owed
from these points in well-dened streams, in some cases at 2 to 3 gpm.
Since the walls were smooth and the construction joints straight, it was
feasible to use a pressure plate, or surface packer, tted with an 0.5-in.-thick
sponge rubber gasket around its perimeter. Details of the packer are shown
in Fig. 16.8. Such packers may be made to any length. However, the longer
they are, the more force is required to hold them in place. Normally they are
braced against an opposite wall. Surface packers can also be used to stop
seepage from porous concrete, as described from a portion of the engineers
report on this eld work.
The pump hoses were connected and the pump actuated. When the
tracer dye in the grout was observed coming out of the lower
petcock, this was shut off. Pumping was continued and when tracer
dye owed from a petcock (not shown in Fig. 16.8) located above
the grout pipe to indicate that air and ground water had been
eliminated from behind the plate, that petcock was closed. With
these two exits closed, the grout could then be forced into the
honeycombed concrete. Dye eventually was seen seeping from
ssures well beyond the area covered by the plate. By pumping
FIGURE 16.8
slowly, gel was made to form in these ssures, thus extending the
effectiveness of the pressure plate.
Grouting with the plate, as just described, differs from the packer
method in that the grout must enter the voids against the ow of water
rather than with it; thus, additional pressure is required.
Good penetration was achieved, and the leaks covered by the plate
were stopped, as were some extending a considerable distance beyond the
plate. The tracer dye, mixed in with the grout, offered a ready means of
detecting the travel of the grout through the ssures.
Sealing isolated cracks and construction joints is more generally done
by pumping grout through packers placed in drilled holes. The following
excerpt from the engineers report describes typical eld procedures:
Drilling Holes/Placement of PackersOne-inch holes were drilled
in the vicinity of the leaks to the point of intersection of the
construction joints, 8 to 10 inches from the surface. An electric
handheld diamond coring drill was used. Next, packers were
inserted in the holes and tightened to provide a pressure-tight seal.
After placing a packer, it was necessary to effect a seal around the
construction joint over an area sufcient to enable the grout to
travel and subsequently gel without becoming dissipated. The seal
was achieved by forcing lead wool into the joint. In addition, a
2 6 4 6 48-inch plank, covered on one surface with a half-inch
layer of sponge rubbrer, was placed against the joint and rmly held
by 2 6 4s braced against the opposite wall.
Pumping Grout/Dye TracerA hand-operated, equal volume, dual
piston pump was connected to the previously secured packer. Grout
was formulated to give a gel of about 12 seconds.
Red dye mixed with the chemical grout served to trace the ow
and indicated the time required for the grout to travel through the
conned area and out to the surface. This determined the duration
of effective pumping time, which proved to be only a few seconds.
Slow, steady pumping at less than 1.2 gallons per minute proved
most effective. Some chemical was lost due to imperfections in the
seal along the joint but this decreased as the solution began to gel.
Pumping was continued until it took more than a reasonable
effort to operate the pump handleabout 20 pounds. At this point,
after a 30-second waiting time, the pump was disconnected and the
sealing board and packer removed. The leakage had been arrested.
Sealing seepage through a nite number of channels is possible and
generally practical when the channels exist as cracks and ssures in an
plate. Prior to the start of the next irrigation season, seepage had been
reduced to between 2000 and 3000 gpd, an amount that could be handled by
the regular sump pump system. It was known, however, that seepage would
increase greatly as the new seasons irrigation began.
While the repair effort was going on, a 50 ft section of tunnel was set
aside as a test section to evaluate chemical grouting as a solution to the
seepage problem. Five days of work in the tunnel demonstrated that
grouting with acrylamide-based materials was an economically feasible
method for sealing existing leaks and for handling anticipated seepage as the
water table continued to rise. The test program demonstrated the presence
of continuous channels at the plate laps along the bolt lines through which
grout would travel, effectively sealing the bolt holes. Tests also showed that
grout hole spacings as much as 4 ft apart along the laps were adequate and
that grout volumes of 10 to 15 gal per hole were needed. Both lateral and
circumferential joints could be treated in this fashion. Based on the test
grouting, specications were prepared, and a grouting contract was let at
about the time the second irrigation season would start.
Grout holes were placed by drilling a 38 in. hole through the inner plate
at the lap and either threading the hole or cementing a square threaded tab
over the hole. Spacing of circumferential holes was 5 to 6 ft, longitudinal
spacing was 4 ft. Grout plant hoses would be attached to the threaded holes
through a nipple and valve placed as soon as each hole was nished. Holes
were placed and water-tested prior to grouting, and the results of the water
test (take, pressure, and time of movement to observation holes) were used
to set the pumping parameters and the gel times. Grouting pressures were
not permitted to exceed 45 psi. In general, the volume per hole was 5 gal or
less at gel times shorter than a minute, and pumping rates were around 0.5
to 0.75 gpm.*
Grouting was carried on over a 4-month period in rolled steel
structures, neoprene joints, and concrete to steel joints as well as in the
tunnels. Grouting work extended through and was completed about a
month after the completion of the second irrigation season. In the tunnels
themselves, 4400 holes were grouted with 16,200 gal of grout, averaging
3.7 gal per hole and 7.6 gal per linear foot of tunnel (many holes did not
accept grout). At the completion of grouting, practically all seepage inow
had been sealed.
Problems requiring seepage control may occur very gradually over a
period of many years, or even because our perception of personal safety (or
* The grout plant used was a specially designed equal volume system with an output of 0.2 to
1.2 gpm. Gel times were controlled by varying the catalyst percentage in the solution tank.
legal liability) change with time. Such was the case in Milwaukee, where a
130-year-old cave system and brewery museum, owned by Miller Brewing
Company, had to be closed. Leaking groundwater had caused a slippery,
unsafe condition on the slate oors [3].
The arched caves are 150 ft long and as deep as 60 ft below ground
surface, with walls up to 44 in. thick. The walls were constructed of large
cut-limestone blocks faced with a brick lining. The soil outside the tunnel
caves is clay. A layer of deteriorated block and granular soil surrounds the
tunnels. The caves were used to store beer until 1906, when they were
abandoned in favor of the (then) new refrigeration systems. The caves were
made into a brewery museum, and opened to the public in 1950. Annually,
some 150,000 visitors are attracted. Seepage through the walls had made the
tunnel oors increasingly slippery and unsafe, and nally necessitated the
closing of the museum.
Numerous attempts were made to seal the tunnels by working from
the surface. None of these attempts was successful. Work was then started
from the inside in 1983. Grout holes were placed by the grouter, McCoy
Contractors (Milwaukee, Wisconsin) on 18 in. centers, through the walls
into the surrounding backll. Using AC-400 at gel times varying between
30 sec and 4 min, 3000 gal of grout were injected into about 900 holes
(representing about 45% of the total job). Grout pressures were kept below
the overburden pressure. Figure 16.9 shows details of the grouting
operation. A year of monitoring indicated a 95% seepage cut-off. The rest
of the work was then completed with 5000 gal through 1200 holes. The
museum has since re-opened.
1
in. (1.5 mm),
When grouting cracks whose exposed openings exceed 16
it is often worthwhile caulking those openings prior to grouting. This
reduces loss of grout, permits working at longer gel times, and provides a
pressure backing to permit grout to ow into the crack against the seepage
ow. A useful discussion of case histories where such procedures were used
is in Ref. [4]. One of the Problems discussed in Reference 4 is shown in
Fig. 9.3. The concrete was badly cracked, with ssures extending from the
upstream face to the downstream face, as shown in Fig. 16.10. Total
seepage was as high as 5000 gpm. Part of the rehabilitation program
consisted of lling the ssures with cement grout. In order to contain the
cement grout until it set, the ssures had to be sealed at their exposed ends.
Figure 16.11 shows how this was done at the detail located on Fig. 16.10.
The open ends of the ssures were caulked to seal them (see number 1 on
Fig. 16.11). Short holes were then placed (see number 2) to intersect the
ssure, which was then sealed with chemical grout. Long holes (see number
3) were drilled behind the sealed ssure for cement grouting. This program,
when completed, reduced the total ow to 10 gpm.
FIGURE 16.9
FIGURE 16.10
Cross-section sketch.
FIGURE 16.11
ground surface. Some time after construction, every construction joint and
crack began leaking, necessitating the installation of a sump pump. Shortly,
this unit was in continuous operation at 25 to 36 gal per min. In order to
eliminate this continual expense, as well as to avoid the contamination of
several thousand bushels of grain if pump failure occurred, remedial
measures were required. Three options were available:
1.
2.
3.
Replace the elevator pit with a new one, properly sealed during
construction.
Install an expensive fail-safe pump system with battery backup.
Seal the existing structure.
The owner elected the third option, and had tried unsuccessfully to pump
sealers around the outside of the pit, prior to contacting a grouting
company.
Holes were drilled on a regular pattern through the walls and oor.
Each hole was closed with a valve as soon as sand was seen running in. Then
vertical grout holes were placed on about 4-ft centers about 12 ft from the
structure perimeter. Sodium silicate grout, catalysed with ethyl acetate and
formamide, with gel times ranging from 18 to 25 min were pumped through
the grout pipes, and the valves inside the pit were opened to draw the grout
toward the pit. By controlling the gel time and the pumping rate, grout was
made to set up at the pit walls, effectively sealing the pit one section at a
time. After 10 years of exposure, the pit was still completely dry.
16.5
SUMMARY
16.6
REFERENCES
16.7
PROBLEMS
16.1
16.2
16.3