1. USE OF SPECIAL HYDRATED LIME
IN THE DESIGN OF
GROUTING MORTARS
D. Lesueur, C. Joly, D. Puiatti, F. Verhelst, J. Burdin
Lyon Oct 17, 2011
Congrès AFTES 2011
1

2. Outline
• Back Grouting Mortars
• High Surface area Slaked Lime (HSSL)
• First use of HSSL in tunnel grout: The Groene-Hart
tunnel
• Latest use of HSSL in tunnel grout: The security
gallery of the Frejus tunnel
• Conclusions
Congrès AFTES 2011
2

3. Outline
• Back Grouting Mortars
• High Surface area Slaked Lime (HSSL)
• First use of HSSL in tunnel grout: The Groene-Hart
tunnel
• Latest use of HSSL in tunnel grout: The security
gallery of the Frejus tunnel
• Conclusions
Congrès AFTES 2011
3

4. Back Grouting Mortars
•
Tunnel bored with TBM with shield
•
Unique specifications for each tunnel
– Fluid
• Fill the annulus between walls and segment rings
• Pumpable over a large period of time
– Stable
• No segregation over time and under pressure
(bleeding)
– Resistant
• Match the mechanical properties (and
permeability) of the surrounding
rock
• Resist the mechanical stresses
– Cost effective
Soil/Rock
• Minimize additives and binder content
Congrès AFTES 2011
Tunnel Grout
Segment Rings
4

5. Back Grouting Mortars
•
Different types of grouts depending on
tunnel context
– Active grouts
• cement-based
– Semi-inert grouts
• fly ash + hydrated lime
– Inert grouts
• fly ash or ground limestone
– Gravel
Soil/Rock
Tunnel Grout
Congrès AFTES 2011
Segment Rings
5

6. Outline
• Back Grouting Mortars
• High Surface area Slaked Lime (HSSL)
• First use of HSSL in tunnel grout: The Groene-Hart
tunnel
• Latest use of HSSL in tunnel grout: The security
gallery of the Frejus tunnel
• Conclusions
Congrès AFTES 2011
6

7. Hydrated (or Slaked) Lime
Quicklime
AT
HE
CaO
calcium oxide
T°>900°C
H2O
calcium carbonate
2
CO
Limestone
CaCO3
HEAT
Hydrated Lime
Ca(OH)2
calcium hydroxide
Congrès AFTES 2011
7

8. High Surface area Slaked Lime
•
Patented Lhoist hydration
technology
•
Tradename Proviacal® SP
•
High reactivity grade
– 3 times more surface area (BET
method with nitrogen
adsorption)
– 3 times more porous volume
(BJH method with nitrogen
adsorption)
Congrès AFTES 2011
8

9. Outline
• Back Grouting Mortars
• High Surface area Slaked Lime (HSSL)
• First use of HSSL in tunnel grout: The Groene-Hart
tunnel
• Latest use of HSSL in tunnel grout: The security
gallery of the Frejus tunnel
• Conclusions
Congrès AFTES 2011
9

10. First Use: Groene-Hart Tunnel Grout
•
Bored in 2002-04 in the Netherlands
•
Tunnel characteristics
– Thalys High Speed railway between
Rotterdam and Amsterdam
– Built by Bouygues + Koop Holding Europe
– Central 7.2 km of tunnel bored in soft soil
with the then-world biggest TBM (14.87 m
diameter)
Congrès AFTES 2011
10

11. Groene-Hart Tunnel Grout
specifications
Normal
Break in / out
< 10-4 m/s
< 10-4 m/s
2,000 kg/m3
2,000 kg/m3
> 1.25 kPa
> 1.25 kPa
to be measured
to be measured
Bleeding
<2%
<2%
Flow test
45 cm
45 cm
Permeability
Density
Yield stress
Filter loss
7.5 min / 2 bars
Pumpability
Until 24 hours
Compressive
Strength
0.5 MPa after 90 days
Congrès AFTES 2011 1.5 MPa after 24 hours
11

12. Groene-Hart Tunnel Grout formulation
(60,000 m3 in total)
Mix 1
Mix 2
0/2 Slurry
kg/m3
820
1,140
2/8 Gravel
kg/m3
400
-
Proviacal® SP
kg/m3
60
70
Fly Ash
kg/m3
300
300
Plasticiser
l/m3
3.6
5
Stabiliser
l/m3
0.2
0.35
Congrès AFTES 2011
12

13. Easier design with
High Surface area Slaked Lime
•
Benefits of Proviacal® SP as compared to standard lime
– Less lime
• 82 to 65 kg/m3
– Less plasticiser
• 5.6 to 3.6 l/m3
– Less stabiliser
• 0.35 to 0.2 l/m3
•
How does it work?
– Pozzolanic reactions
• high surface increases early set
– Rheology stabilizer
• stabilizes yield stress and flow
Congrès AFTES 2011
13

14. Outline
• Back Grouting Mortars
• High Surface area Slaked Lime (HSSL)
• First use of HSSL in tunnel grout: The Groene-Hart
tunnel
• Latest use of HSSL in tunnel grout: The security
gallery of the Frejus tunnel
• Conclusions
Congrès AFTES 2011
14

15. Latest Use: Frejus Tunnel Grout
•
Being bored from 07/2011 until end
2012
•
Tunnel characteristics
– New security gallery of the Frejus
tunnel linking France (Modane) to
Italy
– Built by Razel + Bilfinger Berger
– 5.5 km in France + 3 km in Italy
– 9.46 m diameter in hard shale
Congrès AFTES 2011
15

16. Frejus Tunnel Grout feasability study
•
Feasability study performed at LERM (Arles)
•
Based on the following specifications
Slump
> 20 cm after
3 – 5 hours
Fluidity
12 - 20 s
Settling
< 5 % after 3 hours
Compressive Strength
> 1 MPa after 28 days
Congrès AFTES 2011
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17. Frejus Tunnel Grout possible design
F1
F2
F3
F4
0/4 Sand
kg/m3
1,255
1,170
1,170
1,255
Fly Ash 1
kg/m3
230
230
230
Fly Ash 2
kg/m3
230
Prov. SP
kg/m3
50
50
50
50
Air ent.
l/m3
2.8
2.8
4.2
2.8
Superpl.
l/m3
4.2
4.2
4.2
4.2
Water
kg/m3
257
250
250
190
Congrès AFTES 2011
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18. Frejus Tunnel Grout results
F1
Slump
F2
F3
F4
26.5
0h
cm
23.5
25.5
24.5
5h
cm
20.3
21.4
21.1
7h
cm
24h
cm
13.1
16.3
17.0
19.4
t/m3
2.01
1.99
1.97
2.05
Air volume
%
8.7
7.3
7.8
9.8
Fluidity
s
13.1
16.4
16.0
11.0
Density
Compres.
Strength
21.5
5j
MPa
0.6*
6j
MPa
8j
MPa
1.9
14j
MPa
3.3
1.9
1.7
3.5
2.7
Congrès AFTES 2011
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19. Frejus Tunnel Grout
•
High Surface area Slaked Lime currently in use for the
Frejus tunnel
Fresh mortar
manufactured
in plant
Fresh mortar
transported to
TBM
Congrès AFTES 2011
with permission of
RAZEL BILFINGER
19

20. Frejus Tunnel Grout
•
High Surface area Slaked Lime currently in use for the
Frejus tunnel
Mortar
pumping unit
TBM speed of
475m per
month
Pompe d’injection du mortier
Congrès AFTES 2011
with permission of
RAZEL BILFINGER
20

21. Outline
• Back Grouting Mortars
• High Surface area Slaked Lime (HSSL)
• First use of HSSL in tunnel grout: The Groene-Hart
tunnel
• Latest use of HSSL in tunnel grout: The security
gallery of the Frejus tunnel
• Conclusions
Congrès AFTES 2011
21

22. Conclusions
• High Surface area Slaked Lime (Proviacal® SP)
is a promising ingredient for grouting mortars
• Validated in prestigious projects
– Groene Hart tunnel, Frejus tunnel
• Pozzolanic ingredient and rheology stabilizer
for active and semi-inert grouts
• Cost effective (less lime, less additives)
Congrès AFTES 2011
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23. Thank you for your attention
Congrès AFTES 2011
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