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GSP 136 Innovations in Grouting and Soil Improvement

QUALITYANDQUANTIFICATIONINROCKDRILLINGAND
GROUTING
1

DonaldA.Bruce, DouglasM.Heenan ,andDavidB.Wilson

ABSTRACT
This paper reviews best of current practice concepts under four broad
categories.TheconceptofaQuantitativelyEngineeredGroutCurtain(QECG)is
heldtobethemostresponsivelevelfordesignpurposesanditsbasiccomponents
are described. In rock drilling the principles of Measurement While Drilling
(MWD) are reviewed to illustrate how maximum geotechnical benefit can be
achieved from every production drill hole. An introduction is provided of
contemporarystandardsforfieldtestingofgrouts.Fourthly,theadvantagesof
using Advanced Integrated Analytical (AIA) systems to collect data, monitor
progress,keeprecordsandreports,andgeneratetechnicalanalysesaredescribed.
INTRODUCTION

1.

Notable advances have been made within the last few years in drilling and
groutingprocessesusedforrockmasstreatment.Thesehavemarkedlyimproved
boththedesignandperformanceofgroutingworks.Manyfactorscanbecitedas
contributorstothisremarkablerateofprogress,includingthetechnicalchallenges
posed by the projects themselves (typically remedial in nature and frequently
conducted in quite adverse conditions), developments in equipment, deeper
understandingofgroutmixdesignandperformanceissues,andfarmorerigorous
approachestoQA/QCandverification.
This paperreviews what theauthors consider tobebest ofcurrent practice
underthefollowingmajortopics:
1
2
3
4

designphilosophy,
drillingoperations,
fieldtestingofgrouts,and
automatedgroutingmonitoringandanalysis.

2.

DESIGNPHILOSOPHY

2.1

HistoricalPerspective

Prior to the 1980s, grout curtains were not assigned specific engineering
propertiesthatcouldbeusedindesignandinsubsequentconstructionsoasto
achievespecificperformanceresults.Atthelowestendofdesignsophistication,
1

Geosystems,L.P.;P.O.Box237,Venetia,PA15367,U.S.A.;PH(724)9420570;FAX
Advanced Construction Techniques Ltd.; 10495 Keele Street, Maple, ON L6A
1R7,Canada;PH(905)8329800;FAX(905)8329802;dheenan@agtgroup.com

2 (724)9421911;dabruce@geosystemsbruce.com

3 Gannett
Fleming, Inc.; P.O. Box 67100, Harrisburg, PA 171067100, U.S.A.; PH
(717)7637211x2448;FAX(717)7631808;dwilson@gfnet.com
1

GSP 136 Innovations in Grouting and Soil Improvement

the curtain configuration was selected only on the basis of empirical rules of
thumbrelatedtoappliedhydraulicheadandtypeofdam.Frequently,thecurtain
configuration had little relevance to the actual geologic conditions, and
consequently they were often neither technically nor costeffective. At the
highestendofdesignsophistication,thecurtainsweredesignedonthebasisof
soundexperiencecoupledwithagoodunderstandingofthegeologicconditions.
Shortcomingsofcurtainsdesignedpriortothe1980sincludedthefollowing:
1. Subsurface investigations were performed to explore the stratigraphy and
structure,butboringdepthswereoftensetatpredetermineddepthsratherthan
tailored to define the relevant geologic conditions. Curtain configurations
wereoftensymmetricalacrossthesiteeventhoughthisgeometryfrequently
bearslittleresemblancetothegeologicconditionsrelevanttogrouting.This
resulted in curtains being deeper than necessary in some areas and of
insufficient depth in others, thereby being neither technically nor cost
effective.
2. Waterpressuretestingmayhavebeenincorporatedintheprogram,butthe
results were rarely incorporated into design in a meaningful or rational
manner.
3. Geologicinvestigationssometimesdelineatedfractureorientations,butlittle
attention was ordinarily paid to fracture spacing, fracture size, or fracture
characteristics. Holes were not always oriented so as to intercept primary
fractures,andtheintervaloverwhichcriticalfracturesystemswasintersected
wasofteninadequate.
4. Specificdesign parameters andprojectperformance requirements werenot
generally established (e.g., specific residual seepage rates and pressure
distributions). Therefore, the grouting goals were often unclear and the
programs subject to curtailment solely on the basis of economics when
constructionbudgetswereexceeded.
5. Grout curtain performance, at the time of design, was assumed not to be
materiallyaffectedbythequalityofwork,thecontractingprocedures,orthe
qualityofinspectionprocedures.
Houlsby(1982,1990),Weaver(1991)andothersthroughthe1980sandintothe
1990spublishedawealthofinformationthatpromotedamuchmorerational
approachtogroutingbasedoncarefulsiteinvestigationandsitecharacterization,
matchinghighqualityfieldtechniquestothesiteconditions,andperformingat
leastsemianalyticalapproachestogroutingdesignandanalysisoffieldresults.
WilsonandDreese(1998)firstcoinedthetermQuantitativelyEngineeredGrout
Curtain (QEGC) to describe a methodology whose goal is to take the design
approachtoanadvancedlevel,inwhichallelementsofthedesignareperformed
basedonquantitativeanalysesandconsiderations.
2

GSP 136 Innovations in Grouting and Soil Improvement

2.2

QuantitativelyEngineeredGroutCurtain(QEGC)

Itisfirstessentialtoproperlycharacterizethesite,withparticularregardtothose
propertieswhichwillimpactthegrouting,includinglithological,geostructuraland
hydrogeologicalproperties.Onlythencantheprojectperformancerequirements
belogicallyandrealisticallyset,regardingacceptableresidualseepagerates,flow
pathsand/orpressuredistributions.Themanyfactorsimpactingthesedecisions
werelistedbyWilsonandDreese(1997).Suchdecisionsarebestmadebythe
DesignerinconcertwiththeOwnerandanyBoardofConsultantswhichmay
havebeenconvened.
In the QEGC design approach, the grout curtain is not treated as a vague
impervious barrier. Rather, it is treated as an engineered structure with a
specific geometry and specific hydraulic conductivity that interacts with the
naturalgeologicmaterials.
Theissueofassigningdesignparameterstoagroutcurtainishighlycomplex
because the parameters are controlled by design, construction, and inspection
factors.Theachievableresultsaredependentonmanyelementsofthegrouting
process includingthe grouting materials,grout mixes,constructionequipment,
field technique, number of lines utilized, hole spacing, hole orientation,
experience and diligence of the contractor, experience and diligence of the
inspectionstaff,thefieldmonitoringandanalysistechniquesutilizedinevaluating
thecompletedwork,contractualincentivesanddisincentives,climaticconditions,
andotherfactors.Whileextensiveinformationanddiscussionoftheimportance
ofeachoftheseparametersisreadilyavailable,thefactorshavenot,ingeneral,
beencombinedintospecificdesignrecommendations.
Withthesefactorsinmind,WilsonandDreese(2003)identifiedfoursuccessive
levelsofreasonabledesignperformanceexpectationsforbothsingleandtriple
linecurtains,assumingthatinallcasesthevirginpermeabilitywassupportiveof
groutingbeingaviableoption.Theexpectedresultsachievablewhenbestpractice
isutilizedinallelementsofdesign,constructionandverificationaresummarized
inTable1.
3.

DRILLING

3.1

HistoricalPerspective

Thequalityofthedrillingprocessisfundamentaltothesuccessfulandtimely
execution ofagrouting project. Effective drilling systems mustbecapable of
permitting continuous, adequately straight penetration in materials which may
varyfromverysofttoextremelyhardandfromhomogeneoustoheterogeneous.

GSP 136 Innovations in Grouting and Soil Improvement

Table1.ExpectedPerformanceResultsforBestGroutingPractice:Level4
(WilsonandDreese,2003).

Theymustbecapableofprovidingaconstantdiameter,stable(ortemporarily
stabilized) path full depth, from which the drilling debris has been wholly
removed.Inconjunctionwithrockmassfissuregrouting,thedrillingmustleave
everyfissurewhichisinterceptedinascleanaconditionaspossibletofacilitate
entryandtravelofthegrout.Thechoiceofdrillsystemmustideallybedictated
bythegroundconditions,holedepthanddiameter,costnotwithstanding,although
historicalbiasandregionalexperienceareoftenpowerfulfactors.
Otherprojectspecificconsiderationsmayincludeholedeviationpotential,drill
access constraints and the generation of vibrations. Methods mustalso satisfy
projectenvironmentalrestraintsincludingnoise,andflushcontrolanddisposal.
Aboveall,thedrillingprocessmustnotcauseharmordistresstoanystructure
beingpenetrated,oranyadjacentstructure.
Traditionallylittleattentionhasbeenpaidtothegeotechnicalaspectsofgrouthole
drilling,otherthanthetedious,longrunningargumentabouttherelativemeritsof
percussionversusrotarydrilling.Moresignificant,ofcourse,istheargumentwhich
favorswaterasopposedtoairasthedrillflushofchoiceinfissuredrock.

TherearemanytextbooksincludingthosebyAcker(1974),Australia(1997)and
Rao Karanam and Misra (1998), principally dealing with rock drilling. These
works,thoughextremelyvaluableasdetailedreferences,focusonthemechanical
orgeomechanicalaspects,mainlyasrelatedtoblasthole,waterwelldrillingorsite
investigation. On the other hand, contemporary textbooks on grouting tend to
provide little guidance beyond providing descriptions and illustrations of rock
drillingequipment(anddrillbits).

GSP 136 Innovations in Grouting and Soil Improvement

3.2

QuantificationoftheDrillingProcess:MeasurementWhileDrilling
(MWD)

Bruce (2003) provided practical guidance on drilling systems, equipment,


circulationcharacteristics,deviation,andspecificationsalldetailsrelatingto
the goals of providing straight, cost effective, stable boreholes in the correct
positions.HealsodiscussedMeasurementWhileDrilling(MWD)concepts,an
issuewhichissimpleinphilosophy,relativelystraightforwardtoimplement,and
potentiallyinvaluabletothegroutingprogramdesigner.
ThefundamentalconceptofMWDisthateveryholethatisdrilledintheground
isasourceofgeotechnicalinformationontheactualorprobableresponseofthe
rockmasstotreatment.Thisconceptapplies,ofcourse,tositeinvestigationholes,
butequallytoeveryproductiondrillhole.Theinformationcanbecollectedby
twobasicmethods:manualandautomatic.Tobemostuseful,thedatamustbe
studiedandrespondedtoinrealtime.DataprovidedbyMWDcanbecorrelated
with information from nearby conventional exploratory holes to enhance its
stratumrecognitionability.ThemostinformativeinsightswhenstudyingMWD
recordsrelatetotheexceptionsandunexpecteds(Weaver,1991).
Formanualmonitoringofdrillingparameters,theinformationvalueofotherwise
routine drillers logs will be considerably enhanced by careful and periodic
monitoringof:
12345678-

penetrationrate
thrust
torque
flushreturncharacteristics(cuttings,volume)
drillaction
interconnectionsbetweenholes,ortothesurface
holestability
groundwaterobservations

Suchdatacanbeeasilyrecordedbyagooddrilleroranexperiencedinspector
who has been previously briefed about the overall purpose of the exercise.
Readingsshouldbetakenasfrequentlyaspossible,andinanycaseatnomore
than5feetintervalsineachhole.Regardingautomatedmonitoring,industryhas
benefitedforover20yearsfromseveralsuccessivegenerationsofblackboxes
fittedtodrillrigs.Theserecordinrealtimetheparametersnecessarytoquantify
thedrillabilityoftheground,asquantifiedbye,thespecificenergy:
e

= F+
A

2NT
AR

where
3

e
F

= specificenergy(kJ/m )
= thrust(kN)

= crosssectionalareaofhole(m )

GSP 136 Innovations in Grouting and Soil Improvement


14 =rotationalspeed
(revolutions/second)

=torque(kNm)

=penetrationrate(m/sec)

Suchrecords,coupledwith informationfrom otherinsitu investigations,e.g.,


boreholeTVandpermeabilitytesting,provideaveryhighdiagnosticabilitytothe
grouting specialist during the work and allow him to make rational decisions
regardingthepossibleneedformodificationstoassurethatthedesignintentofthe
curtainismet.
4.

FIELDTESTINGOFGROUTS

4.1

HistoricalPerspective

Asiswidelyknown,rockgroutingpracticeinNorthAmericatraditionallyused
onlytwogroutmixcomponents (waterandcement)exceptwhereparticularly
openconditionsand/orflowingwaternecessitatedtheuseofmineral(andother)
fillers,and/orchemicaladmixtures.Thispatternpersisteduntilthelate1990s,
sometenyearsormoreafterEuropeanpracticehadevolvedtowardstheroutine
incorporationofbentoniteandotheradmixturestoprovidestablemulticomponent
formulationsoffarsuperiorfluidandsetproperties(Deere,1982;DePaolietal.,
1992). The simple mixes were field tested using standard API test apparatus
originallydevelopedforthepetrochemicalindustry,withheavyemphasisplaced
ontheaccuracyofbatching,notnecessarilyonthepropertiesofthemixedgrout.
4.2

RoutineFieldQuantificationofMixProperties

Contemporarygroutmixesmayoftencomprisesixormorecomponents(Chuaqui
andBruce,2003).Theyarespeciallyformulatedonasitespecificbasistoprovide
favorablepropertiessuchaslowbleed,superiorresistancetopressurefiltration,
andcontrollablerheology.Thedevelopmentofmixesonanyparticularprojectis
bestdoneinathreephaseprocess.
Duringthefirstphase,aseriesofformulations,eachsuitedforinjectionunderthe
specificsiteconditions,isdevelopedthroughalaboratorytestingprogram.Inthe
secondphase,onsiteandpriortoproduction,themixdesignsarereplicatedto
investigate any changes in properties due to differences in materials, mixing
equipmentorproceduresbetweenthelaboratorytestingandproductiongrouting.
During this phase the baseline data for the quality control program are also
established.Inthethirdphase(productiongrouting)thepropertiesofthegrouts
are verified regularly to ensure that grouts are consistent, and of acceptable
characteristics.
ItiscommontofindthatcontractorswillprovideonsiteawellequippedQA/QC
facility,runbyaQCtechnicianormanager,onallbutthesmallestprojects.They
arethereforeabletoquantifyandverifythestandardfluidgroutproperties,as
showninTable2,aswellastoconductunconfinedcompressivestrengthtesting
ofhardenedsamples.Specificprojectchallengescanalsobeaddressed.For
6

GSP 136 Innovations in Grouting and Soil Improvement

example,GauseandBruce(1997)describeasimpledeviceforquantifyingthe
washoutpotentialofgroutsplacedinflowingwaterconditions.
Table2.StandardFieldQualityControlTestsforHighMobilityGrouts(HMGs)
(ChuaquiandBruce,2003).
EQUIPMENT

TEST

MarshFunnel

Apparent
Viscosity

Penetrometer/
orShearVane

Cohesion
andTimeto
Initial/Final
Gelation

APIFilter
Press

Pressure
Filtration
Coefficient

DESCRIPTION
TheMarshtimeofthegroutcanbemeasuredinaccordancewith
themethoddescribedinAPIRecommendedPractice13B1witha
Marshfunnelandacalibratedcontainer.Thetestisperformedby
fillingtheMarshconetothebottomofthedumpscreenandthen
measuringthetimefor0.26gallons(1liter)ofgrouttoflow
throughthefunnel.
Eitherapenetrometerorshearvanetypetestwillbeusedto
measuretheamountoftimerequiredforthegrouttoreachinitial
gelation(cohesionof100Pa)andfinalgelation(cohesionof1000
Pa).
ThepressurecoefficientcanbemeasuredwithanAPIfilterpress.
Thetestisperformedbypouringa0.42quarts(400ml)grout
sampleintothetopofthefilterpress.Thesampleisthen
pressurizedto0.7MPA.Thetestisrununtilallthewateris
expelledfromthesample.Thevalueofthepressurefiltration
coefficientisthencalculatedwiththefollowingequation:
Kpf=

5.
5.1

250ml
Graduated
Cylinder
Glass

Bleed

BaroidMud
Balance

Specific
Gravity

VicatNeedle

Initialand
FinalSet
Times

volumeoffiltratex1
volumeofsamplex(timeinminutes)(1/2)
Thebleedcapacityofthegroutcanbemeasuredinaccordance
withthemethodASTMC940witha0.26quart(250ml)graduate
cylinder.Thetestisperformedbypouringgroutintothecylinder
tothe0.21quart(200ml)level.Thesampleisthenleft
undisturbedfortwohoursbeforetheamountofbleedwateris
measured.
Thespecificgravityofagroutcanbemeasuredinaccordanceto
themethoddescribedinAPIRecommendedPractice13B1witha
BaroidMudBalance.TheBaroidmudbalanceisacalibrated
scalethatisusedtomeasurethespecificgravity.Micromotion
flow/densitymetersandhydrometersarealsousedinpractice.
TheinitialandfinalsettimescanbedeterminedwiththeVicat
needletestingapparatus.Thevicatneedleissetatthesurfaceof
thegroutsampleandreleased.Initialsetisreachedwhenthe
needleonlypenetrates1inch(25mm).Finalsetisreachedwhen
theneedledoesnotpenetratethesurfaceofthegroutsample.

AUTOMATEDGROUTINGMONITORINGANDANALYSIS
HistoricalPerspective

Recognitionofthepotentialbenefitsofautomatedmonitoringordatarecording
systems for grouting started in the 1960s (Weaver, 1991). Use of electronic
measurementdevicesmatedwithcomputerswasrecognizedashavingsignificant
potentialalmostassoonasdesktopcomputerscameintobeingintheearly1980s
(Jeffries,1982)(Mueller,1982).TheU.S.BureauofReclamation(USBR)was
the first federal agency in the United States to experiment with the use of
computersformonitoringofgrouting.ThefirstsystemwasutilizedatRidgeway
Damin1982,buthadnumerousproblems.However,thisexperimentresultedin
theUSBRdevelopingacomprehensivehardwareandsoftwaresystemthatwould
7

GSP 136 Innovations in Grouting and Soil Improvement

provide,generate,andrecordalltheinformationthatwasneededformonitoring,
control,andanalysisofgrouting(Demmingetal.,1985).TheUSBRimplemented
itsuseatStillwaterDamin1985althoughsignificantproblemswereexperienced
with consistently maintaining data signals to the recording equipment on this
project.Duringthesametimeperiod,theU.S.ArmyCorpsofEngineersbegan
usingportablesiterecorderstoobtainrealtimegroutingdata,butseverefield
reliabilityproblemswerealsoexperienced(Houlsby,1990).
Lateryearssawdramaticimprovementsinboththenumberandtypeofflowand
pressuremeasuringdevices,computerhardware,dataacquisitionsoftware,and
data management and display software. It has been proven that the use of
computer monitoring systems clearly allows rock fissure grouting to be more
technicallyeffective,performedatalowercost,andinlesstime(e.g.,Wilsonand
Dreese,1998).
5.2

AdvancedIntegratedAnalyticalSystems(AIA)

Dreeseetal.(2003)determinedthattherewerefundamentallythreelevelsofrock
groutingtechnologiestheninuse.Thesecanbesummarizedasfollows:
Level1:Dipstickandgagegeneralpracticepriorto1997.
Level2:Realtimedatacollection,displayandstorageelectroniccollection,
display and limited analysis. Recommended as the minimum level
acceptable for any project over $250,000 and/or of critical
significance.
Level 3: Advanced Integrated Analytical (AIA) System this represents a
majoradvanceonLevel2byprovidingintegrationofdatacollection,
realtime data display, database functions, realtime analytical and
query capabilities, and CAD. The first operational system was
introducedintheUnitedStatesin2001andwasrecommendedforuse
on projects over $750,000 in value or on any project with severe
consequencesofpoorperformance.
Thesystemcurrentlyadvocatedbytheauthorsisatotallyintegratedsystemfor
datacollection,monitoring,recordkeeping,reportingand,mostimportantly,real
timeonsiteandoffsiteanalyses.ItnotonlycontainsallthefeaturesofLevel2
technology,butalsoincludesrealtimegraphicaldisplayofgeologicfeaturesand
stratigraphy,holegeometry,watertestdata,andgroutingdata,whichisprovided
throughcustomizedprogrammingdevelopedwithinAutoCAD.AutoCAD,like
therealtimemonitoringsoftware,readsdatafrom,andwritesdatato,arelational
database.Thedatabaseallowsforthegenerationofstandardandcustomreports
and also allows queries to the database to search for relevant information. In
addition, the AutoCAD programming is also directly linked to this realtime
database, which permits realtime graphical display of grouting results on a
sectionalprofile.Utilizingtherelationaldatabase,thesystemisabletoperform
practically unlimited, complex realtime grouting program analyses and can
displaythegroutingresultsonasimpletounderstandandinterpret,visualcolor
displayonaprofile.Patterns,anomalies,complianceornoncompliance,and
8

GSP 136 Innovations in Grouting and Soil Improvement

areasofspecialinterestareimmediatelyevident.Thesystemisequippedwith
multiple monitoring stations, each with three monitoring screens to allow the
operatortoobserveorperformmultipleoperations.
TheconceptofAIAisamajordevelopmentincomputermonitoringandanalysis
ofgrouting.Italsofurtherreducesonsiteinspectionstafftimeandoptimizesthe
results bydecisionmakersviathedatadisplayoptionsandtheremoteaccess
capabilities.
6.

FINALREMARKS

It is notuncommon forall drillers tobeassociatedwith thelikeablerogue


stereotypethatsomeoftheirbrethrendo,infact,exemplify.Equally,groutersare
routinelydubbedaspractitionersofblackartswheresmokeandmirrorsprevail
andtrustmeisthebasisforperformanceverification.Tobreakthismould,the
authorshaveattemptedinthispapertoidentify,infourcriticalprocessesofrock
treatment technology, the best current standards of quality and quantification.
NorthAmericanprojectsobservingthesestandardswillbeatleastonaparwith
thoseconductedanywhereelseintheworld.
References
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DistributedbyAckerDrillCo.,Inc.,Scranton,PA.246p.
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