1 For official use only Doc.

WRD 9(523) November 2009

BUREAU OF INDIAN STANDARDS PRELIMINARY DRAFT COLGROUT MASONRY IN DAMS- CODE OF PRACTICE

(Not to be reproduced without the permission of BIS or used as a STANDARD)

Last date for receipt of comments is 30 Dec 2009

FOREWORD Uncoursed rubble masonry for dams is extensively used till date. With a view to keep pace with construction speed and to get expected performance from masonry work, more advanced techniques are required to be researched, experimented & implemented. Colgrout Masonry is one of them which satisfies the requirement of strength and durability and at the same time, being impervious, is particularly suitable for water retaining structures in Indian conditions. It has been used in upstream septum of gravity dams in Maharashtra and results are encouraging. Its use for modern structures is increasing steadily. Need was, therefore, felt to publish a code of practice to serve as a useful guide to field engineers. In preparation of this standard, valuable assistance has been derived from the practices followed for construction of various colgrout masonry dams in Maharashtra. For the purpose of deciding whether a particular requirement of this standard is complied with, the final value, observed or calculated, expressing the results of a test or analysis, shall be rounded off in accordance with IS 2:1960 Rules for rounding off numerical values (revised). The number of significant places retained in the rounded off value should be the same as that of the specified value in this standard. 1. SCOPE 1.1 This code covers requirements regarding quality of material and general construction practices for colgrout masonry used in dams & other massive structures. The code aims at control of colgrout work with a view to ensuring strength, durability, impermeability and uniformity.

1.2 This code requires to be supplemented by special instructions, if any, for each job.

2.

REFERENCES

The following standards contain provisions which through reference in this text, constitute provisions of this standard. At the time of publication, the editions indicated were valid. All standards are subject to revision, and parties to agreements based on this standard are encouraged to investigate the possibility of applying the most recent editions of the standards indicated below : IS No. 269:1989 383: :1970 455:1989 456:2000 460(Pt 1):1962 1121(Pt 1 ) :1974 Title Specification for 33 grade ordinary Portland cement (Fourth Revision) Specification for coarse and fine aggregates from natural sources for concrete (Second Revision) Specification for Portland slag cement (Fourth Revision) Plain and reinforced Concrete Code of Practice (Third Revision) Specification for test sieves : Part I Wire cloth test sieves (Third revision) Method of test for determination of strength properties of natural building stones: Part 1 Compressive strength (First Revision) Method of test for determination of water absorption, apparent specific gravity and porosity of natural building stones (First Revision) Method of test for determination of durability of natural building stones (First Revision) Specification for Portland pozzolana cement Part 1 Flyash based (Third Revision) Construction of Stone Masonry Code of practice Part 1: Rubble Stone Masonry (First Revision) Specification for sand for masonry mortars (First Revision) Code of Practice for Preparation and Use of Masonry Mortars (First Revision) Method of Test for Permeability of Cement Morter and Concrete Specification for supersulphated cement Concrete Admixtures Specification (First Revision) Code of practice for permeability test for masonry (during and after construction) Construction of spillways and similar overflow structures Code of Practice

1124:1974

1126 : 1974 1489: (Pt):1991 1597 (Part I):1967 2116 :1980 2250 : 1965 3085:1965 6909: 1990 9103:1999 11216 :1985 11155:1994

3. 3.0 3.1

TERMINOLOGY For the purpose of this code, the following definitions shall apply. Bond An interlocking arrangement of structural units in the masonry to ensure stability.

3.2

Bond stone Selected long stones used to hold the masonry together transversely.

3.3

Coefficient of permeability : The rate of flow of water under laminar flow conditions through a unit cross sectional area of porous medium under a unit hydraulic gradient and at a standard temperature of 270 C.

3.4 3.5

Colgrout double drum mixer : The mixer used for preparing colgrout mortar. Colgrout flow meter : Flow meter used for measuring the flow of colgrout mortar.

3.6 3.7 3.8

Colgrout masonry : Resultant masonry by injection of colgrout mortar in pre-packed stones. Colgrout mortar or Colloidal grout : A mixture of cement, fine aggregate and water and admixture, if any, mixed at high speed in colgrout double drum mixer.

3.9

Colgrouting : Inserting colloidal grout with some suitable pressure to fill up voids, in the prepacked stones or in the body of dam.

3.10

Hammer dressing : Rough surfacing to a stone by means of a spall hammer.

3.11 3.12

Interstice Void or space between adjacent placed stones. Laitance An extremely fine film of material of little hardness which may form on the surface of freshly laid masonry.

3.13

Lugeon - It is the water loss in liters per minute per meter depth of the drill hole under a pressure of ten atmosphere maintained for ten minutes in a drill hole of 46 to 76mm diameter.

3.14

Sand : Natural sand or sand prepared from crushed stone, gravel or such other inert materials.

3.15

Pozzolana : An essentially siliceous material which in itself possessing no cementitious properties, in finely divided form and in the presence of water, react with calcium hydroxide at ordinary temperature to form compound possessing cementitious properties.

3.16

Stretcher stones (Pin header) : Selected long stones embedded vertically in the interior of colgrout masonry to form a bond between successive courses.

3.17 4. 4.2

Slurry : Paste of cement and water. MATERIALS Cement pozzolona Ordinary Portland cement, Portland slag cement, Portland cement and Super Sulphated cement used for colgrout masonry

work in dams and other massive structures shall comply with the requirements of IS : 269-1976, IS : 455, IS : 1489-1976 and IS : 6909 respectively. masonry. 4.2 Admixture - Admixture including pozzolanas, air entraining agents, wetting agents, etc. shall be used only under specific authorization and wherever so permitted, the proportions and methods of use shall be specified by the engineer-in-charge. The chemical admixtures shall conform to IS : 9103-1999
$..

Special cements may also be specified for use in dam

4.2.1 Materials permitted as admixtures shall have established merit for improving any specific quality of the mortar without causing deleterious effects. 4.3 Sand The sand shall conform to IS 2116:1965 and IS 383:1970 . 4.4 Stone 4.4.1 Stone for masonry - The stones for masonry shall be hard, dense, durable, tough, sound and clean. They should be free from decay, weathered faces, soft seams, adhering coatings, sand holes, veins, flaws, cracks, stains and other defects and shall have as far as possible, uniform colour and texture. Stones not uniform in colour, texture and/or with stains may be permitted after proper tests. The stone shall be taken from quarries approved from geological and engineering considerations. The size of stones shall normally vary from 0.05 to 0.01 cum. No stone shall weigh less than 25 kg. No stone weighing between 75 kg and 150 kg shall be less than 225 mm in any direction and no stone weighing between 25 kg and 75kg shall be less than 150 mm in any direction.

4.4.1.1 Spalls Spalls with the minimum dimension of 200 mm to 100 mm shall be used to wedge into the interstices of stones. They shall not normally exceed 10 percent of the volume of colgrout masonry.

4.4.2 Stone for Coursed Face Work The height of the stone for face work shall be uniform and is recommended to be 300 mm including mortar joint. The length and depth of the face stone shall not be less than the height of the stone. At least 50 percent of the stones shall have length more than twice the height of the stone. At least one third of the remaining stones shall be bond stones projecting not less than 2 times the height into the masonry. The remaining shall be header stones with depth not less than 1 times the height of the stone. The stones shall be hammer dressed on face and one line chisel dressed on bed, top and sides for a minimum depth of 75 mm up to which the stones shall be true and rectangular. Beyond 75 mm depth, the stones may be tapered but the tail end of the stones shall have at least half the area of the faces. Bushing on the faces of the stones shall not project more than 40 mm.

4.4.2.1 Header stones The header stones shall not be less than 300 mm in length and one and half times the height in depth.

4.4.2.2 Stretcher stones The stretcher stones shall not be less than 600 mm in length and not less than its height in depth.

4.4.2.3 Bond stones The bond stones shall not be less than 300 mm in length and two and half times the height in depth.

4.4.3 Stone for Uncoursed Face Work Stones for uncoursed face work shall be of selected stones meeting the requirement of stones for coursed face work masonry (Ref. 3.4.2) except that the stones shall be hammer dressed and nearly rectangular.

4.4.4 Tests Samples of stone from approved quarry or new quarry shall be tested for compressive strength in accordance with IS 1121(Part 1 ). The compressive strength testing shall be conducted with the load parallel to the bedding plane and also perpendicular to the bedding plane. The stone samples shall also be tested for water absorption in accordance with IS 1124 , and for soundness in accordance with IS 1126 to ensure suitability of stones for masonry.

4.5 Water - Water used for mixing mortar, grout and also for washing the stone and curing masonry shall conform to the requirements of IS 456. 4.6 Colgrout Mortar 4.6.1 The colgrout mortar shall consist of cement, sand, water and other approved admixtures, if any, each complying with its respective specifications in accordance with 3.1 to 3.3, mixed in the proportions as may be defined, by weight. The proportions of materials entering into the mortar shall be based on

laboratory studies. The moisture content of the sand shall be taken into account in proportioning the mix. The fineness modulus of sand shall be 2.6 to 3.0. Pozzolanic material may also be mixed, if directed, in proportions fixed by the engineer-in-charge. If directed, suitable air entraining agent may be used to

improve the quality and workability of the mortar. The exact proportion of airentrainment shall be determined by actual tests. 4.6.2 All materials forming the mortar should be measured by mass except for water which may be measured by mass or by equivalent volume. Where weighbatching is not possible, due consideration to bulkage of sand and its water content shall be given. 4.6.3 The mortar shall be mixed in a colgrout double drum mixer only. Single drum mixer should not be allowed. Mixer should not be loaded in excess of the rated capacity of mixer. Following general principles shall be followed: a) The speed of mixer should be 1500 to 2000 rpm. b) The thoroughness of mixing and adequacy of mixing time so as to give colloidal state to the mortar shall be tested at the start of the job and at intervals as may be considered necessary. The minimum mixing time generally specified is as follows: Mixing cement and water in first drum 15 to 20 seconds Mixing of cement slurry and sand in second drum 40 to 60 seconds. Overall time for one mix of colgrout mortar 60 to 90 seconds.

c) The compressive strength of colgrout mortar shall be specified for the particular job. The exact proportions for the cement, sand and water for the mortar shall be fixed after conducting test for compressive strength. Trial mixes shall be run at the project laboratory for obtaining the desired flow with the help of following table. Water Cement Ratio & Water Requirement for Trial Mortar Mix.:

Cement : sand Water/Cement Water for 50 proportion ratio cement in liters 1:2 0.62 to 0.70 31-35 1:3 0.76 to 0.84 38-42

kg

Mortar flow shall be maintained 40 to 50 cm measured on colgrout flow meter.

4.6.4 Testing of mortar shall be done in accordance with IS 2250. In special cases where specimens of different sizes are used such as 15cmx30cm cylinder / 15 cm cube, necessary correlation shall be established and such tests may be adopted for quality control. Tests on mortar shall be regularly conducted and shall comprise compressive, tensile and permeability tests.

4.6.4.1 Frequency of sampling The frequency of sampling of materials and colgrout mortar during works shall be as follows:

4.6.4.1.1 Cement - One sample for every 50 ton of cement.

4.6.4.1.2 Sand - One sample for every 500 cum of colgrout masonry or one sample in a week, whichever is earlier.

4.6.4.1.3 Mortar flow : Minimum three flow meter tests per working shift per mixer. 4.6.4.1.4 Sampling of mortar cubes i) Up to 100 cum of colgrout masonry work per day, one sample per shift per mixer and ii) For every additional 100 cum of colgrout masonry work per day, one sample per shift per mixer.

4.6.4.2 Standard of acceptance.

a) The strength of one sample shall be taken as the average of at least three test specimens taken from single batch of mortar. If the individual specimen result differs by more than 15 percent of the average of three specimens, the average of the remaining two specimens shall be worked out. If the individual

test results of two specimens of mortar do not come within 15 percent of the average the whole set of results shall be rejected from analysis. Over a given period of time as specified by Engineer-in-charge, not more than 10 percent of specimens tested shall have a compressive strength less than 80 percent of the required strength and the average of all tests shall equal or exceed the required strength. Compressive strength of 15cm cube of colgrout mortar after 28 days shall be equal or higher than the stipulated values as given below: Proportion of Cement : Sand Compressive strength in kg/cm2 of in Colgrout mortar 15cm size cubes at 28 days Lab.Strength Field Strength 1:2 1:3 190 150 153 117

Sr.No.

1. 2.

b) Permeability of mortar as used on work shall not give a coefficient of permeability greater than 2.5 x 10
-8

mm/sec as per IS 11216 when

tested as per IS 3085(Part IV) for all proportions of mortar.

5. PREPARATION OF FOUNDATION :-

5.1 Colgrout masonry in contact with rock foundation After completion of rough excavation of foundation, scaling and trimming for the final removal of all slabby or drummy rock or any loosened mass shall be done by chiselling picking, barring and wedging. Any weathered or decomposed rock remaining should be removed, the doubtful areas cleaned out to sufficient depth and back-filled with concrete in richer proportion. If foundation conditions require consolidation grouting, then it may be carried out after laying one lift of colgrout masonry. In case steps are required to be provided in the foundation, those shall conform to IS 11155.

5.1.1 Immediately prior to placing colgrout masonry, the foundation shall be moistened and coated by brush with a thick cement slurry (1 cement : about 2 or 3 water by volume).This shall be done within few minutes before building colgrout masonry. This slurry shall be spread only on a small area of about 1.0 sqm at a time and mortar spread immediately thereafter. A layer of mortar 50 to 75 mm

thick, shall be spread over the slurry and worked into all the irregularities of the rock surface, by trowels, bars or brushes. The composition of this mortar shall be the same as used in the colgrout masonry work. The first course of stones shall be carefully pressed in to the mortar so as to force the mortar around the corners. The layer of mortar shall be made thicker, if required, to suit stones of sizes larger than 0.06 cum.

5.2 Colgrout masonry in contact with fresh Colgrout masonry - Surface of Colgrout masonry shall be treated as follows, before laying fresh Colgrout masonry over it. Loose stones, if any, shall be removed. Mortar joints shall be scraped with iron rods and the exposed faces of the stones shall be wire brushed. The surface shall be cleaned with air-water jet. The water collected in the depressions of masonry shall be removed by sponge or cloth. Surface shall be coated by thick slurry (1 cement : 2 or 3 water by volume) just few minutes before laying the next lift.

5.3 Colgrout masonry in contact with old colgrout masonry - Surface of old colgrout masonry which has been exposed for a long time that is more than 28 days shall be treated as follows. Loose stones, if any, shall be removed. Old mortar joints shall be scraped to a depth of 15 mm or wet sand blasted and washed with air-water jet. Immediately prior to placing of colgrout masonry, the old masonry surface shall be treated in the same way as for rock foundation described in 4.1.1

5.4 Colgrout masonry in contact with concrete Concrete surface, which has hardened shall be roughened by chipping to a depth of 40mm to 25mm so as to remove top mortar film and get a rough surface for starting masonry and surface shall be treated in the same way as for rock foundation described in 4.1.1

6. COLGROUT MASONRY

6.1 General - The structure shall be built true to line, plumb or curved or as directed in a workman like manner, suitable aids like templates, scaffoldings etc. shall be used. The construction shall be done in compartments of different size & shapes. The area of each compartment shall be so fixed that it can be

10

colgrouted continuously in one shift of working. It shall not be more than 25 to 30 sq.m. and height not exceeding 1.0 m. For Upstream & Downstream surfaces of dam, utmost care shall be taken to face work. The face work may be in wall compartment fashion or in colgrout masonry using shuttering. In case of

opening, the concrete of appropriate grade shall be used instead of colgrout.

6.1.1 The maximum height of colgrout masonry allowed to be constructed at a time shall be 1 m. No fresh masonry shall be laid within 24 hours over colgrout masonry previously laid. 6.1.2 In the same block (monolith) the difference in level of masonry layers

should normally be not more than 1.5 m.

6.2 Partition wall for compartments Partition walls of compartment shall be 45 cm thick U.C.R. masonry without regular face work, height not exceeding 1 m and in mortar proportion as used in colgrout masonry. This wall act as a

shuttering for colgrout masonry which later becomes integral part of colgrout masonry. Adequate headers and stretchers shall be provided for ensuring horizontal and vertical bond with the colgrout masonry. The minimum number of headers shall be at the rate of one per square meter of face work. Masonry walls shall be constructed in accordance with IS 1597(Part 1).

6.3 Laying of stones The stones shall be free from dirt and surface-dry before being placed. The quarried stones shall be thoroughly cleaned and watered before they are brought to the block for placement. The stones shall be placed in the work after knocking off weak corners and edges with a masons hammer and after clearing scales of foreign matter, if any. Stones shall be placed manually and interlocking in a layer in the compartment so that bigger dimension is along horizontal plane and they may not act as wedges and force out the adjacent stone. If stones once kept in position are to be adjusted, they shall be lifted clear and reset; they shall not be moved one over the other. Adequate headers shall be provided for proper horizontal and vertical bond with next surrounding layers. The minimum number of headers shall be more than one per 4 sqm area to be bonded. A row of vertical stretcher stones shall be erected at about 2 m center to center both ways so that there is at least one vertical stone for every 4 sqm area for the bond with next lift. Stone spalls of 200 mm to 100 mm size shall be

11

wedged in to the interstices between the adjacent stones whenever necessary to avoid thick beds or joints and to achieve maximum density. There shall be a good collection of stones and spalls within easy reach of each mason to enable proper selection of stones for laying and they should be kept continuously replenished.

6.3.1 Layers - The thickness of layer shall be 35 cm. Such layers shall be continued to be arranged till the predetermined height of the compartment is reached. 6.3.2 Placing of G.I. Pipes : 75mm diameter perforated GI pipes shall be placed at 1.5m center to center ( or at least one pipe per 2.15 sqm area) and about 25 mm above the bottom while pre-packing the stones. Pipes shall be withdrawn simultaneously as colgrouting of each hole is in progress.

6.4 Mortar injection: The colgrout mortar shall be injected with sufficient pressure by upward penetration method through each perforated GI pipe. The insertion of mortar shall proceed from one end in direct sequence so as to achieve uniform height of the mortar in all pipes in any section of colgrouted masonry and GI pipe shall be raised as hole is getting filled up. The mortar shall not be brought up to the top level of the stones, but to about half the height of the top stone so as to ensure a good key for next lift.

6.4.1 Colgrout masonry should invariably be done during day light hours.

6.5 Mortar intake - Quantity of mortar in the colgrout masonry shall normally be 40 percent to 45 percent.

6.6 Colgrout masonry in U/S septum - When colgrout masonry is used in upstream septum of dam the hearting masonry downstream side of the septum shall be constructed first. Adequate protruding headers shall be provided for proper horizontal bond with surrounding layers of colgrout masonry in the septum so that question of separation of U/S septum from the hearting masonry does not arise. 6.7 Cleaning of laitance - On filling the compartment, the slurry shall be roughened by rods, punja, wire brushes etc. The laitance that comes to the

12

surface after initial setting shall be cleaned out by wire brush and removed by water jetting the surface.

6.8 Protection The fresh masonry shall be protected against vibrations, any other movements and rains, which might injure it before its final set. Stones shall not be allowed to be dumped over the masonry before its final set. Walkways for inspection, supervision, roughening at top surface etc. shall be provided to ensure that green masonry is not disturbed before it sets.

6.9 Curing Arrangements shall be made to protect the fresh masonry against rapid drying and to cure masonry. The masonry shall be cured after 4 to 12 hours of construction and water shall be gently sprayed so as to avoid damages. All exposed surfaces of masonry shall be kept continuously moist for at least 21 days.

6.10 Face work The upstream and downstream face work in spillway, nonspillway and power dam sections may be constructed either in wall compartment fashion or in colgrout masonry using shuttering. Face side compartment wall shall consists of face stones hammer-dressed on face and one line chisel dressed on bed, top and sides for 75mm from the front face built with the course normal to the face batter. This work can also be constructed in uncoursed rubble masonry. The work shall be built in header and stretcher fashion and joints shall be break in courses above and below by at least half the height of the course. In case of uncoursed rubble masonry, the header stones shall be placed at about 1 m centre-to-centre. The joints in face work shall not be thicker than 15mm for single-line chisel-dressed stones or 20 mm for hammer dressed stones.

6.10.1 Bond stones in each course shall be so provided that every sixth stone or third header stone is a bond stone. In case of uncoursed face work, the bond stones shall be placed at about 2.5 m centre-to-centre. The bond stones shall be staggered and marked for identification.

6.10.2 The face work shall be struck neatly and smoothed off with a trowel before the mortar takes the final set.

13

6.10.2.1 All pointing shall be done with cement sand mortar 1:3 or richer mix. The sand shall be fine, passing through 600-micron IS sieve (see IS 460) and conforming in all respects to IS:2116-1965.

The joints in masonry to be pointed shall be raked square, for a minimum depth of two times the thickness of the joint within 24 hour of laying of masonry. In special circumstances ,this period may be released to 48 hours. The refilling and pointing shall be done within three days of raking of the joints so as to ensure good adhesion between the two mortars.

6.10.2.2 The joints shall be finished neat, defined, regular and of uniform width. The joints may be filled either flush or raised as required. The surface pointed should be kept wet for 21 days after pointing is completed.

6.10.2.3 It is normal practice to use formwork for U/s and D/s sloping face instead of masonry face work . Where formwork is used, it shall confine the colgrout masonry and shape it to the required line. The forms shall have

sufficient strength and rigidity to hold masonry and sustain the pressure of colgrout mortar being injected without excessive deflection from prescribed lines. Form work made up of only steel shuttering shall be allowed. It should be free from warping and fabricated true to line and shape. The inside surface shall be clean, rigid, watertight ,smooth and free from dirt, shavings, chipping or other foreign matter. Inner surface shall be treated with a suitable non-staining oil to prevent adherence. The forms shall fit tightly over the completed surface so as to prevent leakage of slurry from the masonry. Removal of forms shall never be started until colgrout is thoroughly set and hardened adequately to sustain its own weight and live load which is likely to come on the work for laying of next lift. In normal circumstances, forms shall be struck on expiry of 48 hours from injection of colgrout mortar. However the length of time for which forms shall remain in the place shall be decided by engineer-in-charge. All faces of masonry shall be smooth and sound, free from voids and air holes when formwork is struck. Any roughness or irregularity on the exposed surfaces shall immediately filled up while masonry is green with cement mortar 1 :1, properly trawled and finished. Such patching of surface shall be carried only with permission of engineer-in-charge.

14

6.11 Tests for Colgrout Masonry

6.11.1 In situ Permeability test Permeability tests on colgrout masonry shall be carried out in accordance with IS:11216.

6.11.2 Laboratory Tests

6.11.2.1 Drilling cores from colgrout masonry For testing in laboratory, core of 90 cm diameter and 90 cm depth shall be drilled from colgrout masonry. Drilling shall be done after sufficiently hardening of masonry, preferably after 90 days. One core up to and for every ten thousand cum of colgrout masonry constructed during the season shall be taken.

6.11.2.2 Testing of core in laboratory

6.11.2.2.1 Permeability test Permeability test shall be conducted by central injection method with double rubber packers placed at 60 cm apart in central NX hole of the core. The maximum pressure allowed shall be 3.5 kg/cm2. Standard of impermeability aimed at, shall be a water loss of not more than 2.5 lugeons.

6.11.2.2.2 Density Density shall be obtained by measuring the volume of core and weighing the core. The density shall not be less than 2.40 gm/cc.

6.11.2.2.3 Compressive strength - Compressive strength shall be obtained by ultimate crushing of core on 2000 Ton capacity Compression Testing Machine. The compressive strength obtained on cylindrical core of 90cm x 90cm with L/D = 1 shall be converted for L/D = 2 using conversion curve given in IS 516. The compressive strength shall not be less than 90 kg/cm2 for L/D ratio as 2, for colgrout masonry.