GUJARATH INFORMATICS LTD.

R0 13 .09.2023 For Approval NK CV SN

Revisio
Date Purpose of Issue Originator Checker Approver
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Contents

1. Introduction......................................................................................................................................................4
2. Scope................................................................................................................................................................4
3. Equipment & Materials....................................................................................................................................4
4. Grouting Material and Equipment....................................................................................................................4
5. Construction of Consolidation Grouting...........................................................................................................5
6. Eliminating Measures of Waste, Residue,Slurry and Water.............................................................................7
7. Safety Measures...............................................................................................................................................8
 1. Introduction

2. Scope
This method statement is applicable for consolidation grouting of rock masses using cement grout mix.

3. Equipment & Materials

1. Drilling Machine
2. Drill Rods
3. Grout mixer
4. Grout agitator
5. Grout Centrifugal Pump
6. Valves and Fittings
7. Packers
8. Pressure guage
9. Water meter

4. Grouting Material and Equipment

4.1 Grouting Material
Grouting material for consolidation grouting mainly consists of cement OPC Type 1, water, admixture
like sand, fly ash, etc and additive (in case required).

4.2 Drill-hole grouting equipment

The drill-hole operation of the consolidation grouting construction is drilled with the hydraulic drill,and
the inspection hole uses the geological drilling rig for construction. 3SNS high pressure grout inject
pump. Machine in the slurry station is the NJ-400 type high speed mixer wiith small size and strong
production capacity.

4.3 Other Equipment

Pressure guage:
To moniter the pressure on the grout as long as grouting is in progress.
Packers: Packers are used to seal off or isolate a portion of grout hole that allows grout to be
injected under pressure into a specified section of the hole. Packers are installed either at the top
of the hole, also called the hole collar or at other locations along the length of the hole. It is also
most often installed at the collar of the hole for consolidation grouting operations, when the hole is
grouted in single stage. The double-packer arrangement is used to grout isolated sections in
consolidation grouting operations.
For consolidation grouting a maximum pre-sure of 7 kg/cm2 is normally recommended but this may be
increased up to 20kg/cm2 in special cases provided that there is adequate cover and the joints in the
rock arc not Iikely to open up by this pressure.

5. Construction of Consolidation Grouting

a) Drilling holes
b) Cleaning and washing holes
c) Testing holes - water pressure testing,
d) Grouting holes, and
e) Testing the grouted zone for efficacy of grouting

5.1 Drilling Holes:

Drilling will be done by hydraulic drilling method. The grout hole of 50mm diameter and the depth
should be between 0.75 D and D where D is the finished diameter of the tunnel, except in special
reaches where it could be more. The maximum depth is 15m as per IS 5878-PARTVII-1972.
After completion of drilling up to required depth and while retrieval of drill rod from the bore hole
flushing of bore hole shall be done.
For consolidation grounting, the drilling and grouting are recommended to be done from invert
upwards doing the crown holes last. However, where the invert hole is exactly at the bottom and it
cannot be drilled and grouted without interfering with other operations in the tunnels this should be
done last.
Pattern of grout holes can be hexagonal pattern or set of holes in one vertical plane.

5.2 Cleaning and washing holes

On completion of the drilling of a stage and before injection, the holes should be washed by allowing the drilling
water to run until the return from the hole is reasonably clean. The quantity of water ftowio, into the hole
during the period should be adequate and generally not less than 15 l/min.

5.3 Water Pressure Test

Before the start first stage consolidation grouting two holes one in the crown and the other in the left or right
side wall alternatively shall be checked to assess the rock permeability values.
Permeability tests were conducted before consolidation grouting to decide the pattern of drill holes, grouting
planes, consistency of grout mix and finally to check the efficiency of grouting operation. Permeability tests were
conducted up to a maximum pressure of 7 kg/cm2 in the drill holes drilled up to 6 m depth into the rock.
Coefficient of permeability was determined in lugeons at 7 kg/cm2 water pressure. The pressure for WPT will
not be more than those laid down for the grouting of particular stage.
5.4 Grouting
Initially grout mixing shall be done in the ratio of 4:1 to 1:1.Required amount of water as per the above
ratio shall be fed in to the mixer and mix ratio, mixing period shall be fed on to the mixer. Portland
cement shall be fed in to the mixer.
1) Grouting method
a) The consolidation grouting should be conducted in accordance with the principle of the
sequence and the density. The different rows of the grouting holes and the different holes of
the same row can be divided into two sequences construction, and also can be sequenced only
by row but not hole or otherwise the opposite.
b) When using the top-down section grouting method, we should use the grouting packer to block
at 0.5 m above the top of each grouting section to prevent leakage. As for the hole section
without watering of the orifice, it can be uncondensed after grouting. But it should be
condensed in the complex areas like fault and fracture zone, and the time should be
determined according to the geological conditions and design requirements.
c) The consolidation grouting hole of this project is deep to 5m into the rock, and it conducts a
first grouting method.
d) It records the parameters like grouting pressure, amount and so on by a grouting automatic
recorder.
e) After grouting, we should close it for condensation towards the grouting hole that carries
aoutflow slurry or up-back slurry. And it should be condensed in the complete geological
conditionareas like fault and fracture zone, and the time should be determined according to the
geological conditions and design requirements.
2) Grouting pressure and water cement ratio
The pressure of the consolidation grouting of this projects is supposed to be 0.3Mpa, and the final
number shall be determined by the grouting experiment. And the grouting pressure and injection rate
should be strictly controlled during the grouting.
The water cement ratio of the consolidation grouting slurry can be conducted by four levels including
2:1, 1:1, 0.8:1 and 0.5:1, to be specific, the ratio of open the grouting slurry can be 2:1. And the
grouting slurry is transformed from dilute to concentrated. And when the grouting pressure remains
constant and the injection rate decreases, or when the injection rate remains constant while the
grouting pressure continues to rise, the water cement ratio should not changed. And it can also use a
single ratio of stable slurry if it is demonstrated feasible through grouting experiment.
3)Slurry transforming standard
When using multi-stage water cement ratio, the principle of the slurry is as follows:
1) When the grouting pressure remains constant and the injection rate decreases, or when the
injection rate remains constant and the grouting pressure continues to rise, the water cement ratio
shall not be changed.
 2) When the injection amount of a single ratio slurry has reached more than 300L, or the
grouting time has reached 30 min, while the grouting pressure and injection rate are not significantly
changed, it should be replaced by a concentrated grouting slurry;
3) When the injection rate is more than 30L/min, it can leap frog to concentration according to
the specific circumstances of construction.
In the process of grouting, when the grouting pressure or the injection rate suddenly changes a
lot,we should immediately identify the reason and take corresponding measures.
4) Grouting finishing standard
When consolidation grouting is under the maximum designed pressure, it should finish after 30
min continuously grouting while the injection rate is no more than 1L/min. And if it is not able to reach
the finish standard for a long period, we should report to all participants to work out a solution
together.. 5) Hole sealing
The method to close the consolidation grouting hole is the "pipe grouting hole sealing method"
or the "full grouting hole sealing method".
To the consolidation grouting hole constructed by the citation (buried) pipe method, it should
use the 0.5:1 concentrated slurry instead of the dilute slurry in the hole after the grouting reaches the
designedfinish standard, and when the slurry pipe drains the 0.5:1 concentrated slurry, we should
conduct the holesealing, close the grouting and seal the hole.

5.5 Testing for Efficacy of Grouting

This testing may be done by drilling the holes in between the grout planes and by testing water intake
in these test holes. If this is compared with the water test made before the grouting, this water test
will give an indication of the efficacy of grouting. Further grouring of this test hole and intake in this
hole will give further indication. It is only after these tests that the engineer-in-charge may decide on
increasing the number of grout planes if required. The inspected number of holes in the single point
water pressure test should not be less than 5% of total number of grouting holes.

6. Eliminating Measures of Waste, Residue,Slurry and Water

In the process of each parts of the construction side, set up the temporary sump in the lower
construction site and around slurry stations, so the construction sewage could precipitate here and
bedrained into the sedimentation tank with the pump, and then be concentrated drained after
precipitation,and clean up the sediment and waste slurry, etc. at any time, at last, transport them to
the designated place. #s for the grouting area without co&er weight, the surface residue will be
backhoe loaded andtransported to the designated place after cleaned up by hammer.

7. Safety Measures
The following safety measures shall be followed during the entire construction work:
1) Experienced Crews of Drillers and assistants shall be engaged in works. All the rotating parts will
be guarded.
2) House-keeping to be done on daily basis. ,
3) Hard hats, reflecting jackets, steel toe-capped footwear and necessary PPE will be worn by all
workers at all time during their presence at site.
4) No loose clothing shall be worn by workmen while working at site. Safety induction and tool
box talk shall be conducted periodically.
5) All workers shall be trained for awareness and sequence of operation. Fire extinguishers shall
be in place.
6) First aid kit and first aider must be available for entire duration of work