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  • 1. 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
  • 2. 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 35
  • 3. 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 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 Italian-Thai Development PCL. 1 July 2013 Page 3 of 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 : ______________________
  • 4. 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 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 Italian-Thai Development PCL. 1 July 2013 Page 4 of 35
  • 5. 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 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. Italian-Thai Development PCL. 1 July 2013 Page 5 of 35
  • 6. 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 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 Italian-Thai Development PCL. 1 July 2013 Page 6 of 35
  • 7. 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 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. Italian-Thai Development PCL. 1 July 2013 Page 7 of 35
  • 8. 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 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. Italian-Thai Development PCL. 1 July 2013 Page 8 of 35
  • 9. 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  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. Italian-Thai Development PCL. 1 July 2013 Page 9 of 35
  • 10. 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 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. Italian-Thai Development PCL. 1 July 2013 Page 10 of 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
  • 11. 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 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. Italian-Thai Development PCL. 1 July 2013 Page 11 of 35 Materials Proportion Cement 500 kg Water 850 litre Bentonite 50 kg
  • 12. 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 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. Italian-Thai Development PCL. 1 July 2013 Page 12 of 35
  • 13. 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 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. Italian-Thai Development PCL. 1 July 2013 Page 13 of 35
  • 14. 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 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 Every Day X N/A W/O R W/O MS/T007/2 C Site Engineer 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 Every Day X N/A W/O R W/O MS/T007/3 C Site Engineer 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 Every Day X N/A W/O R W/O MS/T007/3 C Site Engineer 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
  • 15. 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 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 : ___________________________
  • 16. 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 Primary Grouting Shift Report (Form No. MS/T007/2, Rev. C) Italian-Thai Development PCL. 1 July 2013 Page 14 of 35 Completed by Site Engineer Agreed by QC ER 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
  • 17. 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 Secondary Grout Material Test (Form No. MS/T007/3, Rev. C) 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 Italian-Thai Development PCL. 1 July 2013 Page 15 of 35 Completed by Site Engineer Agreed by QC ER Name :___________________ ( ) Engineer Date : _____________________ Name :___________________ ( ) Engineer Date : _____________________ Witnessed Point-Optional by : __________ ( ) Date : ___________________________
  • 18. 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. A Note: 1 Div. = (Div. x 2.3942 + 0.9710) x 9.81 N Calibrated Date May 23, 2013. Italian-Thai Development PCL. 1 July 2013 Page 16 of 35
  • 19. 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 Secondary Grouting Shift Report (Form No. MS/T007/4, Rev. C) 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
  • 20. 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 Attachment A Grouting Material for shield Tunneling Work: Proposal for Mix Design and Testing Method Italian-Thai Development PCL. 1 July 2013 Page 17 of 35 Completed by Site Engineer Agreed by QC E Name :__________________________________ ( ) Engineer Date : __________________________________ Name :_______________________________ ( ) Engineer Date : _______________________________ Witnessed Point-Optional b ( ) Date : _________________
  • 21. 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 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. Italian-Thai Development PCL. 1 July 2013 Page 18 of 35
  • 22. 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 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. Italian-Thai Development PCL. 1 July 2013 Page 19 of 35
  • 23. 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 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 Italian-Thai Development PCL. 1 July 2013 Page 20 of 35
  • 24. 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 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 Italian-Thai Development PCL. 1 July 2013 Page 21 of 35
  • 25. 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 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. Italian-Thai Development PCL. 1 July 2013 Page 22 of 35
  • 26. 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 Measurement of Bleeding Italian-Thai Development PCL. 1 July 2013 Page 23 of 35
  • 27. 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 Measurement of Consistency Italian-Thai Development PCL. 1 July 2013 Page 24 of 35
  • 28. 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 Measurement of Specific Gravity Italian-Thai Development PCL. 1 July 2013 Page 25 of 35
  • 29. 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 Measurement of Gel Time Italian-Thai Development PCL. 1 July 2013 Page 26 of 35
  • 30. 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 Attachment B The Laboratory Test Program for Primary and Secondary Grouting Works Italian-Thai Development PCL. 1 July 2013 Page 27 of 35
  • 31. 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 The Laboratory test Program for Primary and Secondary Grouting Works. Italian-Thai Development PCL. 1 July 2013 Page 28 of 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
  • 32. 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 Attachment C ASTM C939-02 Standard Test Method for Preplaced- Aggregate Concrete (Flow Cone Method) Italian-Thai Development PCL. 1 July 2013 Page 29 of 35
  • 33. 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 Italian-Thai Development PCL. 1 July 2013 Page 30 of 35
  • 34. 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 Italian-Thai Development PCL. 1 July 2013 Page 31 of 35
  • 35. 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 Italian-Thai Development PCL. 1 July 2013 Page 32 of 35
  • 36. 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 Italian-Thai Development PCL. 1 July 2013 Page 33 of 35
  • 37. 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 Italian-Thai Development PCL. 1 July 2013 Page 34 of 35
  • 38. 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 Italian-Thai Development PCL. 1 July 2013 Page 35 of 35
  • 39. 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 Attachment D ASTM D4830-84 (Reapproved 2001) Standard Test Method for Density of Bentonitic Slurries Italian-Thai Development PCL. 1 July 2013 Page 36 of 35
  • 40. 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 Italian-Thai Development PCL. 1 July 2013 Page 37 of 35
  • 41. 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 Italian-Thai Development PCL. 1 July 2013 Page 38 of 35
  • 42. 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 Italian-Thai Development PCL. 1 July 2013 Page 39 of 35
  • 43. 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 Italian-Thai Development PCL. 1 July 2013 Page 40 of 35