POLYURETHANE GROUTING

BY:
RISHI KAITHALA
CONTENTS:

Introduction
Types of polyurethanes
Applications
Implementation
Advantages and Disadvantages
A case history on polyurethane applied project
Conclusion
INTRODUCTION:

What is Grouting?
Grouting is a process of placing a materials into cavities in concrete or masonry
structure for the purpose of increasing the load bearing capacity of a structure,
restoring monolithic nature of a structural member, filling voids between precast
connections, providing fire stops, stopping leakages and soil stabilization.

What is Polyurethane Grouting?

The use of Polyurethane Resin as a grouting material is called as Polyurethane
Grouting. Grouting with polyurethane [PU] resins represents an effective method of
improvement of mechanical and sealing properties of soil and rock environment and
constructions.
Types of Polyurethanes:

Single Stage Polyurethane (PU)

One component polyurethane chemical, one component water
HYDROPHILIC REQUIRES WATER FOR REACTION
Expansive reaction due to production of CO2 foam
Sealant/Water Cutoff

Polyurethane Resin (PUR)

Two components polyurethane chemical
HYDROPHOBIC DOES NOT REQUIRE WATER FOR
REACTION
Some PUR may react with water by design
Strength/Stabilization

Epoxy
Not used for large-scale grouting

ansion potential of polyurethane (Joyce 1992)

Types of Polyurethanes:

Technical
Parameters:
Property Polyurethane (PU) Polyurethane Resin (PUR) Epoxy

Mixing Components One Two Two

Hydrophilic
Reaction with Water Hydrophobic Hydrophobic
(required)
Low to Medium Medium to High Low to High
Density
3 - 50 pcf 20 70 pcf 5 60 pcf

Compressive/Tensile Low Low to High Medium to High

Strength 10 500 psi 15 20,000 psi 5,000 to 20,000 psi
Viscosity Low to Medium Low to High Very Low to High
Relative Cost Low Mid to High High

Adapted from (Arndt et al 2008)

Implementation:

General PUR grouting procedure

Drill grout borehole

Sequence and spacing of boreholes has to be designed
according to the project requirements

Insert grouting assembly into borehole

Pressure transfer from grout tube into borehole
Target zones along borehole for improvement

Mix components
Perform mixing as close as possible to the injection site

Inject grout through fractures along borehole Example grout pump. Small and easy to
Stop injection when PUR is seen visibly extruding from mobilize
surface of rock or spike in back pressure is observed
Implementation:
Advantages:

Low viscosity Disadvantages:

Penetrates small fractures
High control resolution Infiltration is unknown
Viscosity Invasive techniques required for verification
Expansion properties Hydrofracturing
Too much injection pressure may cause rock
Set time (seconds) falls
Strength High Cost
Strength
3 4 times the strength of cementitious grouts
Easily mobilized and environmentally inert
Aesthetics
Case Study:

1.West Virginia Coal Mine:

Experiencing multiple roof falls per year

Moisture sensitive shale roof
Roof supports restricting passage through mine
PUR injection chosen for stabilization of roof at
intersections
Case Study:

Plan view
11 boreholes per intersection, staggered
10 ft center-to-center spacing
Case Study:

Cross section:
Target zone between 2 6 ft above
roof chosen to create grout beam for
stabilization
Initial injection performed at
perimeter angled 45 degrees to create
grout curtain
Sequential injection of targeted zone
Case Study:

100% filling of voids

9 of 16 boreholes
Partial filling of voids
4 of 16 boreholes
43% to 93%
No filling of voids
3 of 16 boreholes
0%, 1%, and 9% observed
The boreholes showing no filling of voids were
supported with standing supports.
Verification of infiltration extremely important.
Case Study 2:
CONTINUOUS
CONTINUOUS CURED
CURED FOAM
FOAM COLUMN
COLUMN INJECTION
INJECTION OF
OF SOFT
SOFT CLAY
CLAY FOUNDATION:
FOUNDATION:

DESCRIPTION IF SITE:
Two-lane secondary highway with a width of about 11m.

PROBLEM AT THE SITE:

The shoulder and west lane of the road had experienced creep

settlement requiring periodic asphalt patching which were

applies every 18 months

Which resulted in the asphalt thickness of 0.5m.
Case Study:

GEOTECHNICAL INVESTIGATION:

A geotechnical investigation in 2008

showed that the subgrade soil in the

maximum settlement area consisted of

soft to firm, medium plasticity clay

Two factors contributing the settlement

Consolidation of the soft clay and

additional weight from patching asphalt.

Case Study:

SOLUTION:
A deep polyurethane permeation grout (Prime Flex 920) injection technology was
chosen to improve the strength of the subgrade and consolidate the soft clay
EXECUTION:
Foam injection holes were spaced at about 1.2 m triangular grid intervals for a 15
m length of both highway lanes
A steel casing was used which prevented the soft clays from collapse into the
drilled hole
The column functions as an in-situ pile with both skin friction resistance and end-
bearing resistance.
Within each injection hole, the polyurethane materials usage was about 12.6
Liters per linear meter (or 1 gallon per linear foot). Based on volumes used the
formulated foam columns had an average estimated diameter of 0.56 meter. In
total, 130 foam columns were installed at this project
Case Study:

PROJECT COST:
The project cost was about $170k.

FINAL RESULT:
No further settlement or pavement distress has been observed
since the foam injection and repaving work in August 2011.

ADVANTAGES OF THE SELECTED SOLUTION:

Excavation and removal of the existing pavement structure was
not required
greater depth of subgrade improvement could be achieved
traffic closure was not required
Conclusion:

Polyurethane grouting, as a mature technology, provide a unique approach for settlement issues on both
asphalt and concrete roadways.
Permeation grouts, due to its low viscosity, expansion rate, hydrophobic property, fast set time and
developed construction method, can be used to stabilize the soil in deeper burial depth (6 meter or plus)
and also install a foam pile to increase load-bearing.
This method is considered as a long-term fix to eliminate frequent re-pavement and water erosion
issues. It also helps save the costs for road closure and building detour.
Compaction grout with superior rapid expanding property, can fix the concrete roadways settlements in
hours.
Since polyurethane can contain sand and gravel in the foam, the road structure will stay intact for
decades when applied properly under appropriate conditions.
This saves the costs for multiple mud-jacking in future years.