Use of Special Hydrated Lime for Tunnel Grouts

1Congrès AFTES 2011

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


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


Outline





• Conclusions


• 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• Minimize additives and binder content

Back Grouting Mortars

Soil/Rock

Tunnel Grout

Segment Rings


• 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

Segment Rings

Back Grouting Mortars


Outline





• Conclusions


Hydrated (or Slaked) Lime

Limestone

calcium carbonate

CaCO3

HEAT

Hydrated Lime

calcium hydroxide

Ca(OH)2

Quicklime

calcium oxide

CaO

T°>900°C

HE

AT

CO

2 H2O


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)


Outline





• Conclusions


• 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)

First Use: Groene-Hart Tunnel Grout


Normal Break in / out

Permeability < 10-4 m/s < 10-4 m/s

Density 2,000 kg/m3 2,000 kg/m3

Yield stress > 1.25 kPa > 1.25 kPa

Filter loss 7.5 min / 2 bars

to be measured to be measured

Bleeding < 2 % < 2 %

Flow test 45 cm 45 cm

Pumpability Until 24 hours

Compressive Strength

0.5 MPa after 90 days 1.5 MPa after 24 hours

Groene-Hart Tunnel Grout specifications


Mix 1 Mix 2

0/2 Slurrykg/m3

820 1,140

2/8 Gravel kg/m3

400 -

Proviacal® SPkg/m3

60 70

Fly Ashkg/m3

300 300

Plasticiserl/m3

3.6 5

Stabiliserl/m3

0.2 0.35

Groene-Hart Tunnel Grout formulation (60,000 m3 in total)


• 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

Easier design with High Surface area Slaked Lime


Outline





• Conclusions


• 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

Latest Use: Frejus Tunnel Grout


Slump > 20 cm after 3 – 5 hours

Fluidity 12 - 20 s

Settling < 5 % after 3 hours

Compressive Strength > 1 MPa after 28 days

• Feasability study performed at LERM (Arles)

• Based on the following specifications

Frejus Tunnel Grout feasability study


F1 F2 F3 F4

0/4 Sandkg/m3

1,255 1,170 1,170 1,255

Fly Ash 1kg/m3

230 230 230

Fly Ash 2kg/m3

230

Prov. SPkg/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

Waterkg/m3

257 250 250 190

Frejus Tunnel Grout possible design


F1 F2 F3 F4

Slump 0h cm 23.5 25.5 24.5 26.5

5h cm 20.3 21.4 21.1

7h cm 21.5

24h cm 13.1 16.3 17.0 19.4

Density 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

Compres.Strength

5j MPa 0.6*

6j MPa 1.9 1.7

8j MPa 1.9

14j MPa 3.3 3.5 2.7

Frejus Tunnel Grout results


• High Surface area Slaked Lime currently in use for the Frejus tunnel

Fresh mortar manufactured in plant

Fresh mortar transported to TBM

with permission of RAZEL BILFINGER

Frejus Tunnel Grout


• High Surface area Slaked Lime currently in use for the Frejus tunnel

Mortar pumping unit

Pompe d’injection du mortier

TBM speed of 475m per month with permission of

RAZEL BILFINGER

Frejus Tunnel Grout


Outline





• 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)

Conclusions


Thank you for your attention

Use of Special Hydrated Lime for Tunnel Grouts

Technology

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