World Tunnel Congress 2008 - Underground Facilities for Better Environment and Safety - India

Concreting behind steel liner at large heights – A case study

R.D. Varangaonkar
Gammon India Limited, Mumbai, India

SYNOPSIS: Pump concrete technique is adopted very often on most places. Efforts are made and designs
are improved to pump concrete to longer distances and higher heights. This paper deals with high pressure
concrete pumped to a height of 780m. As on date the world record for pumping concrete is for a height of
535m. To pump the concrete to 780m height, one concrete pump was specially designed and manufactured.
Concrete pipes were also specially designed and manufactured to take up such high concrete pressure
including the pipe jointing clamps. Method for cleaning the pipe was also developed in the eventuality of
chocking of concrete in pipe. A thorough and detailed planning was done to achieve this tough task. This
paper describes in detail the minute planning done for the projects to achieve this tough task.

1. LOCATION Lesser Himalayan Zone. The Project comprises of

85m high concrete dam, 6m diameter concrete lined
Parbati Hydroelectric Project is located in Kullu tunnel 31.6km long and two numbers of inclined
District of Himachal Pradesh which is situated in pressure shafts inc lined at 30 degree each having

Sketch showing a general layout drawing of the project

INTAKE STRUCTURE
3 Nos.DESILTING CHAMBERS

TOSH NALLAH

CONCRETE DAM
DIVERSION TUNNEL HO
RS 6.0
E
R

SH M GAMMON'S SCOPE OF WORK

PARBATI RIVE

O D IA
E LOT PB - 3. INCLUDES HRT
SH
AP FROM RD- 24733 TO 31371 M
E D
H.
R.
T. CONSTRUCTION ADIT
6.0 M DIA CIRCULAR H.R.T. ADIT NO. 3
HURLA NALLAH
TRENCH WEAR
FEEDER TUNNEL BOTTOM ADIT-2 JIW TAIL RACE CHANNEL
PANCHA-HURLA AN
FEEDER TUNNEL-II
3.0 M DIA. TO PRESSUIRE SHAFT AL
LA
SA
H IN
ADIT NO. 1 FEEDER TUNNEL-III
JR
PORTAL EL. 2185.00 IV
SHEELAGARH ER
PANCHA MALLAH
TRENCH WEAR POWER HOUSE
ADIT NO. 3A 4NO.PENSTOCKS 2.5M DIA.
2NO. PRESSURE SHAFTS 3.5M DIA.
ADIT NO. 3A ADIT TO PRESSURE SHAFT TOP
ADIT NO. 3
MANIHAR-PANCHA VALVE HOUSE
FEEDER TUNNEL-I
ADIT TO SURGE SHAFT BOTTOM
TRENCH WEAR APPROACH ADIT
ADIT NO. 2 TO SURGE SHAFT TOP
ADIT NO. 4

17.0 M DIA SURGE SHAFT

DROP SHAFT NO.1 DROP SHAFT NO.2
4.0 M DIA. 4.0 M DIA. ADIT NO. 5
6.0 M DIA
HORSE SHOE SHAPED H.R.T.

A
LAYOUT PLAN

Sketch showing the location of inclined pressure shafts and approach Adits
Adit No. 5 Bottom Adit-2 (for TBM Erection
2 NO. Pressure Shaft
Portal EL. 2100.00 (3.5 M Dia) at Spacing & Further Excavation of 3.5m. dia JIWA NALLAH
(6000Ø D Shaped Length 515m.) of 48m c/c Pressure Shaft
Portal EL. 1332.00 4 No. Penstocks
6000 Ø HRT (2.5 m. Dia at Spacing
Length 640.00m.
6000 Ø D Shaped of 24m c/c
Up Surge Gallery Bottom Adit-1 to Penstock
325m. Long at EL. 2225 Portal EL. 1332.00
Vertical Bend Line
(6500Ø D Shape Length 215m.
6000 Ø D Shaped
Down Surge Gallery
Access to Lower
250m. Long at EL. 2117.50 Manhole SA
IN J
SA

H.R.T. RD 31371m. Approach Adit to Surge R IV

Shaft Bottom Portal EL. 2100.00 ER
IN J

17m. Dia Surge Shaft (6000Ø D Shape Length= 355m.)

R IV

Invert EL. 2106.00m. Power House

Valve House
ER

Approach Adit to Surge (8MX12MX63M) Tail Race Channel

Shaft Top Portal EL. 2230.00 LAYOUT PLAN OF PRESSURE SHAFT & POWER HOUSE
(6000Ø D SHAPE LENGTH= 150 M.)

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length of 1542m. The surface powerhouse of
800MW, consisting of four units. These two
inclined pressure shafts were bored by Double
Shield Tunnel Boring Machine (TBM). The bored
diameter of inclined pressure shaft is 4.8m
diameter.
2. THE TASK
Inclined pressure shaft boring was completed by
TBM and was simultaneously lined by pre-cast
segment lining. The task now left out is to install
the ferrules 3.5m diameter inside the pre-cast lined
tunnel and concrete behind the steel liner, i.e. to fill
up the gap between pre-cast concrete lining and
steel ferrules.
3.50m
4.3m
4.70m
4.88m
Sketch showing the bored diameter, pre-cast segment and steel liner and showing the gap for concrete
Three options were available for concreting –
1. To carry the concrete from top by transit
mixers mounted on trolleys.
2. To pump the concrete from top.
3. To pumps the concrete from bottom.
First two options for carrying concrete from top was
extremely difficult because of :
• It was interfering with the transportation of
ferrules requiring very meticulous interaction
for carrying the ferrules to the location and
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then making arrangement for laying the
concrete pipeline.
• To carry the concrete by transit mixers
mounted on the trolley would be very slow
operation and charging the transit mixers
would be tough or almost unfeasible.
• The pumping of concrete from top at 30 degree
would be difficult because of air trapping.
Laying the pipeline would again interfere with
ferrule transportation.
• Approach to the concrete pipeline would be
only from the trolley which is used for
transportation of concrete.
• Pumping from bottom also needed very
meticulous planning for –
90 THICK PEBBLE FILLING
FOLLOWED BY GROUTING
200 THICK PRE-CAST
CONCRETE SEGMENTAL LINING
400 THICK CONCRETE FILLING
BEHIND STEEL LINER
STEEL LINER
- Arrangement for shifting and extending
pipelines.
- Arrangement for manpower to reach the
location of concrete.
• Considering the advantages and disadvantages
of both the operations, it was decided to pump
concrete from bottom. This will be having
advantage that it will be independent from the
operation of ferrule transportation. Manpower
can also easily reach with the help of
independent winch and trolley from the
bottom. The only problem was to find a pump
 suitable for pumping concrete approximately at Table 1. Pump BP 4000 HDR – 180/125 –
a height of 800m. Specifications & Details

Technical Parameter 4000

3. PLANNING
Motor Output 160 KW
Nominal Speed 1500 rpm
Concreting
Pumping Cylinder 180 x 2000 mm
We checked up various projects all over the world Dia. X Stroke
and could get the information that the maximum Dead Weight 8000 kg
height at which concrete has been poured so far is (incl. oil)
535m. In order to pump concrete at the height of Delivery Pipeline (HP) up to DN 150 (HD) mm
800m, we had to identify a suitable pump capable of Rock Valve Dia. 180 / 180 / 150 HP mm
this operation. We contacted two major pump Max. Hydraulic Oil Pressure
manufacturers from Germany, i.e. Putzmeister and 320 bar
Schwing Stetter. Both these manufacturers have Capacity of Charging Hopper 400 l
agreed to look into the new design of high pressure Diff – Cylinder Dn / dn/ Stroke 125 / 80 / 2000 mm
pump capable of pumping up to 800m height. A Diff – Cylinder Drive* KS SS
pump named BP4000 HDR designed by Schwing Max. Number of Strokes per 17 28
Stetter was found to be suitable for pumping minute
concrete to this height; along with the accessories, Basic Setting of Number of 15 25
i.e. delivery pipelines, couplings, shut-off valve, Strokes
ball catcher, pit catcher (Table 1). Max. theoretical Concrete 45 M3/h 77 M3/h
The ferrule length was 6m. A detailed planning Output
was worked out whether to concrete one, two or Max. Concrete Pressure 154 bar 91 bar
three ferrules at a time. It was found most
*KS = piston-side admission / SS = rod-side admission
economical and faster to adapt to concrete two
ferrules, i.e. 12m length of concrete at a time. The
gap between the pre-cast segment lining and steel
liner was only 400mm and therefore it was not 3.1 Mix proportions of self compacting concrete
possible to vibrate concrete with external vibrators.
Necessarily, it required Self-Compacting Concrete. Grade = M25 A20
It was decided and planned to pour self-compacting Characteristics Strength = 25N/mm2
concrete. A special design mix was done for self-
Standard Division = 4 N/mm2
compacting concrete.
Target Mean Strength = 31.6 N/mm2
Contents

Cement (kg/m3) 315 Viscocity modified Admixture

(Lt/m3) 0.9
3
High Volume Fly Ash (kg/m ) 135 Slump Flow (mm) 712
3
F. A. (kg/m ) 926 T ________ (Sec) 3
3
A10 (kg/m ) 349 V – Funnel Test (Sec) 9
A20 (kg/m3) 426 V Funnel at T ___ (Sec) 3
3
Water (kg/m ) 180 L – Box (h2/h1) 0.93
th 2
w/c 0.4 7 day Strength (N/mm ) 22.81
th 2
C.A : F.A 45 : 55 28 day Strength (N/mm ) 32.89
Super plasticizer (Lt/m3) 3.6

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4. PIPELINE
4.1 Design of Pipe
In order to sustain such a high pressure of above
300 bar, a special pipeline was designed and
manufactured in Germany. Also out of the various
options of pipeline diameters of 100mm, 125mm
and 150mm, it was found that 125mm diameter pipe
would be most suited for this type of work. For such
a high pressure, special pipe was to be
manufactured and in case only one thickness of pipe
was adopted throughout the length, the cost was
coming exorbitantly high. Concrete pressure since
will be reducing from bottom to top, it was planned
to reduce the pipe thickness gradually. Two types of
Suitable Couplings were also designed to sustain this high pressure.
Pump-2
Twin Pump Arrangement
pipe thickness were designed:
• 8.8mm pipe up to the height of 800m.
• 7.1mm pipe beyond 800m up to end
5. TRANSPORTATION & FIXING OF
PIPELINE
Considering 12m concrete at a time, similar
extension of pipeline would be required. To
transport the pipeline to 30 degree inclined location,
rail trolley was specially designed. The trolley was
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designed in such a way that it would not tilt at 30
degree when pulled up. Necessary counter weight
was designed. Five numbers of pipes weighing
approximately 1 ton would be transported at a time
since frequent trips of winch need to be avoided.
Support for the rails was designed and “I” section
was laid down to cross members welded to erected
ferrule. A proper arrangement also was made for
manpower to safely travel on this winch.
5.1 Selection of winch
The special trolley has to travel from 0m to 1542m.
It was since required to be pulled from top,
Pump-1
necessarily the wire rope has to come from a return
pulley which has to be very rigidly and firmly fixed
to take the loads of trolley, pipeline, manpower and
the complete load of the wire rope.
The total wire rope would come to more than
3000m. To accommodate such a large length of
wire rope, a specially designed albatross winch was
imported from Germany.
 Sketch showing inclined trolley, arrangement for rail and cross members and return pulley.
Keeping in mind the safety of the people
traveling on the winch and in the eventuality of
requiring to stop the winch anywhere on the path,
the winch was so designed that the wire rope was
having one core of wire by which winch could be
operated by remote control by the passenger
traveling on the trolley.
Requirement of concrete was only 5 cum/m.
Therefore it was decided that the existing
arrangement of 30 cum batching plant and three
transit mixers will be used. The only addition was to
erect one silo and weighing arrangement for fly ash.
Planning was also required to be done for cleaning
the pipeline. The pipeline would carry concrete
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.013cum/m. This amount of concrete will be stored
in the length of concrete in use at particular
location. The task is to use the concrete in the
pipeline and not allowed to go waste and then clean
the pipe. It was therefore planned to use shut off
valves at designed locations which can be closed
when required.
(i) In case of chocking, a particular section can be
isolated and cleaned.
(ii) Once the concrete is complete, shut off valve at
the bottom can be closed and sponge ball with
water column can be inserted in the pipeline
and with the help of second pump with which
bye-pass line is installed, water or bantonite
slurry can be pumped, pushing the complete
concrete column up and to the location. When
 this sponge ball reaches the top, trap basket
will not allow the ball to cross but complete
concrete can be unloaded to the location. When
the sponge ball reaches the top, water from the
pipeline can be emptied by the by-pass
emptying pipes which unload the complete
water and bantonite slurry into the tank and
cleaning the entire pipeline simultaneously. For
more than 100m of pipeline length, care was
taken that water is not allowed to empty
without a pressurized cleaning scrapper
otherwise concrete may stick to the pipeline
walls.
6. SAFETY
Considering the length of travel, restricted place of
work and tremendous load on the return pulley and
winch, the following safety measures were taken.
Concrete pipeline cleaning using sponge balls
Similarly, following safety measures were taken for
lowering the ferrules :
• Double breaking arrangement on winch.
• Close circuit T.V. at the front point of ferrule
winch.
• No manpower was allowed while ferrules were
shifted.
• Inspection of motor, gear box, winch and wire
rope after each operation and maintenance of
winch every week including the certification
by mechanical engineer incharge.
• Welding for cross girder supporting rail was
done by a very skilled welder and was checked
by foreman every time.
• Return pulley anchoring was checked
everyday.
7. CHRONOLOGICAL COMPLETE CYCLE
• Lowering of ferrules 6m at a time 2 hours
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• Aligning of ferrules at location 2 hours
• Preheating and welding for first ferrule 48 hours
• 48 hours x 2 (for second ferrule) 96 hours
• Concreting of 60 cum 6 hours
• Cleaning the pipeline 1 ½ hours
• Total cycle time for 12m pipeline 107 ½ hours
8. CONCLUSION
• The work is very difficult and hazardous in
nature.
• The working place is also very restricted.
• Working on inclined 30 degree becomes very
strenuous and difficult.
• Selection and design of concrete pump,
suitable concrete pipeline was most important
decision for success of project.
• A detail design was also very important for
transportation of pipes and manpower to the
work location.
In order to avoid any mishaps and consequent
stoppage of work, a detailed planning was required
to be done for smooth operation and successful
completion of work.
BIOGRAPHICAL DETAILS OF THE AUTHOR
R.D.Varangaonkar, graduated in Civil
Engineering from the Regional
Engineering College, Bhopal, Vikram
University Ujjain (MP) ranked 5th in
University, Merit List 1968. He was
placed 17th in merit list of H.S.S.C.
Exam of M.P. Board of Secondary
Education.
 He is Fellow of five premier institutions of India
including Indian National Academy of Engineering &
Member of eleven institutions of various natures.
He has about 40 years of rich experience in
construction of variety of Civil Engineering large scale
projects as under.
• Industrial Structures
• Cooling Towers, Water Tower, T.V. Towers.
• Silos & Prilling Towers.
• Prestressed Concrete Bridges Rail-cum-Road
Bridges.
• Pile Foundation - Large diameter and depth.
• Mega Hydro-Electric Projects.

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