Proposal for Tunnel Stabilization

ROCK STABILITY OF TUNNEL
PROPOSAL FOR CONSOLIDATION, BACKFILL AND CONTACT

GROUTING, EMPLACEMENT OF GEOMEMBRANE & STEEL LINER
OR ENHANCED RCC LINING FOR TUNNEL
GRC JOINT VENTURE

Lala Zar Colony, Old Bahawalpur Road, Multan, Pakistan P: +92 61 4512263 F:
+92 61 4545190
PROPOSAL FOR CONSOLIDATION, BACKFILL AND CONTACT GROUTING, EMPLACEMENT
OF GEOMEMBRANE & STEEL LINER OR ENHANCED RCC LINING FOR TUNNEL
Table of Contents
1. INTRODUCTION: .................................................................................................................................... 2
2. WHY WE NEED TO OPT. THIS PROPOSAL? ........................................................................................ 2
3. Elements for Rock Mass Stability: ............................................................................................................ 3
a. Consolidation Grouting within the Tunnel .............................................................................................. 3
Objectives: .................................................................................................................................................. 3
Methodology: .............................................................................................................................................. 4
DRAWINGS ................................................................................................................................................ 6
b. Backfill Grouting within the Tunnel ........................................................................................................ 6
DRAWINGS ................................................................................................................................................ 6
c. Contact Grouting within the Tunnel ....................................................................................................... 6
Objectives: .................................................................................................................................................. 6
Methodology: .............................................................................................................................................. 7
DRAWINGS ................................................................................................................................................ 7
d. Placement of Geomembrane ......................................................................................................................... 7
e. Treatment of the Extreme Poor Rock Zone in theTunnel ................................................................ 8
Two alternatives are suggested as under: ................................................................................................. 8
i. Treatment by Strenghting of the Concrete Suiting worst Geological Condition ...................... 8
DRAWING .................................................................................................................................................. 8
ii. Installation of steel liner ..................................................................................................................... 8
4. ABSTRACT OF COST: ............................................................................................................................. 9
a. Abstract of Cost with RCC Lining ...................................................................................................... 9
b. Abstract of Cost with Steel Lining ................................................................................................... 10
5. ABSTRACT OF QUANTITIES: .............................................................................................................. 12
6. ROCK MASS CLASSIFICATION – ACTUAL VS FEASIBILITY COMPARISON: ............................ 13
7. GEOLOGICAL MAPPING FOR TUNNEL INLET – SUPPORTING DOCUMENT: .......................... 20
8. GEOLOGICAL MAPPING FOR TUNNEL OUTLET – SUPPORTING DOCUMENT: ....................... 20
9. CONCLUSION: ....................................................................................................................................... 20
10. LIST OF ATTACHMENT................................................................................................................... 20
December 08, 2018 Page 1 of 21

1. INTRODUCTION:
During the excavation of the Karora HPP Tunnel, it has been noticed that the strata
encompassing the Tunnel is extremely heterogeneous including extreme poor rock
zones at places. Rock of Continental and the Oceanic crusts have been encountered in
highly intermixed position. The continental crust rocks comprising Granite and Granitic
gneiss. The oceanic crust rocks consist of ultrabasic (slabs of dunites, peridodite,
pyroxinite, gabbro and amphibolites etc). Most of these have undergone varying
degrees of alteration like chloritization and serpentinization etc. The two different stuffs
(e.g. crustal and oceanic masses) have come together through severe orogenic
deformation plate movements, resultantly the formational contacts are faulted, sheared
and closely intermingled (see cover Photo). The entire masses around the Tunnel are
water bearing and carry enumerable water passages.
The position of the inflow of water at various reaches has been on very high side. The
record shows up to 5040 Cum of dewatering conducted per day for several months.
This has been a unique case in the history of Tunnels in the world.
Keeping in view the brief summary given above, it is needed to keep in mind the future
operative life of the Tunnel structure. It is known that the seepage from the strata is of
vital importance for the life of the Tunnel. This water has to be controlled. For this
purpose, the leakages have to be sealed. It is mainly done through the consolidation
Grouting.
The success of grouting, speacialy in the present situations is estimated to be about

80% to 90%. For further control of seepage water, geomembrane will be installed. It will
help in controlling/routing of the remaining water.
In addition to the Consolidation Grouting and installation of Geomembrane, Contact and

backfill Grouting will be conducted as routine conventional practice in vogue elsewhere
in the World.
2. WHY WE NEED TO OPT. THIS PROPOSAL?

1. The tunnel is unique from geo-engineering point of view.
2. The tunnel is located in the Melange Zone of the Main Mantle Thrust (MMT).
3. Published Literature (books, geological bulletins, case histories and individual
papers) donot carry an analogue elsewhere in the world.
4. The Mélange Zone is the mixture of rocks from the over thrusted Indo-Pak plate
and the under thrusted Ophiolite Belt of the MMT.
5. The Tunnel cover rock consists of broken, moved, rolled, sheared, faulted and
partly digested/recrystalized pieces, blocks, fragments and grains.
6. The strata is interbedded, comprising altra basic and extreme acidic phases, Case
of rounding of masses, intense micro folding and partial indigestion/recystalization
indicate development of Migmatites.
7. Development of migmatites represent an extreme position of pressure and
temperature.

8. The repeated below-outs of slush of heterogeneous lithologies, e.g areas onward

of RD 325 in the inlet tunnel and RD 75-110, 485-578 in outlet side of the tunnel
with huge quantities of water has been unique.
9. Metalliferous (Sulplides) bearing hydrothermal breccia in lumps, have been
obtained from various stretches of the tunnel eg. RD 485-490 of outlet tunnel. It
represents high pressure and temperature conditions. It related to the tectonic
phases or earlier is little known at present. It is however known that chromitites e.g
at RD 415 is part and parcel of the Jajyal-Dubair-Shangla ophiolite and clearly
indicates the genesis of the melange Zone of the Karora Tunnel.
10. The out bursting of water in large quantities and associated continuous flows and
slush, filling the inlet tunnel up to 2.5 meter height for more than two months
proved that the Tunnel rock mass serves as an underground water reservior in
itself. The fact was identified and communicated to concerned quarters way back in
March 24, 2017.
11. Closely spaced rock support measures e.g lattice girders and solid steel arches
provided in the tunnel have got deformed at couple of places e.g around RD 430-
450 and RD 757- 805 of the inlet tunnel and around RD 495-525 of the Outlet
Tunnel.
3. ELEMENTS FOR ROCK MASS STABILITY:
a. Consolidation Grouting within the Tunnel

In this process, fluid grout, usually consisting of ordinary Portland cement and/or
bentonite, accelerators chemical and fine sand is injected into water bearing fractured
rockmass. It seals the water paths and also enhance the rock strength.it is proposed
that ISRM standard is followed.
Objectives:
Consolidation grouting aims at;
 Providing support to poor quality rocks determined through Internationally

approved and applied Q System of rock classification which has been correlated
to the corresponding value of R3-R4 in accordance with the values identified by
the designer of project.
 Consolidation grouting fills the discontinuities in rock such as ruptures, fractures,
joints, pores and voids and thus reduces / eliminates the incoming seepage
water which is harmful to an engineering structure. With the passage of time
accumulation of seepage water causes extra pressure on the crown and walls of
a tunnel thereby causing damages to the structure in years to come.
 Consolidation grouting helps in providing strength to the loose rock of the outer
shell walls of the structure and thus helps increase the life of the inner wall of the
concrete structure.
 Conventional excavation process, involving blasting, add to fracturing in the
peripheral rock mass. The damage can be minimized through calculated / mild
blasting but cannot be completely avoided. To overcome the problem,

consolidation grouting is conducted. Consolidation is also a rock strengthening

measure and is applied in almost all underground excavation works. The extent /
depth of consolidation / grouting holes varies and is adapted in accordance with
the rock class which is evaluated after each run of the blasting.
Methodology:
The methodology to be followed for Karora HPP tunnel is adopted after Norwegian
tunneling society Publication 20 and British Standard the code of practice (BS
5930:2015).
Continuous seepage in the cover rock encompassing the tunnel lead to damaging the
concrete lining. It is essentially required to grout the wall rock to block the undesirable
leakages by filling the joints, fractures, water seepage paths by grouting material,
mainly cement, Bentonite and/or fine sand and accelarator through grout holes already
drilled. The grout with water cement ratio as 1:1, 0:8:1. 0:6:1 will be used. The ratio
can be modified as per site condition depending upon flow of grouting material and final
refusal of grout under particular applied pressure that will be intiated with 0.5 mega
pascal (Mpa) to a maximum of 1.2 Mpa subject to very close watch for noticing and
avoiding hydro fracturing of strata.
Ascending stage grouting method with Mechanical/Pneumatic packers will be

undertaken in high water seepage areas so as avoid grout loss. The central row-hole
(R-5 as shown in the proposed pattern in the crown of the tunnel) will be grouted first
as primary followed by secondary and tertiary holes. This row will be followed by the
two rows (R3 and R-7) on either sides of the crown holes in staggered pattern which
will be arranged in 1.5m distance both within the row and between the rows. The
grouting with the same pattern will be followed by R4 and R6. Lastly the holes in R1
and R9 will be followed by holes row R2 and R8.
As a first step pneumatic down hole hammer or rotary drilling will be carried out. Upon
drilling, the holes will be cleared of residue and debris with compressed air or clean
water.
The orientation of the holes and the drilling tools should be checked prior and during
the drilling process. The allowable tolerance of hole location should not be more than
0.10 m.
As stated earlier, the tunnel rock comprise extreme sheared and shattered zones. It is
believed that drilling in such zones may lead to collapsing of the drill holes. Under such
conditions drilling will be done with casing and perporated grouting pipes inserted and
sealed by proper flexable grout mix of cement and 2-3% bentonite, subject of
adjustment before removing the casing.
Grouting in a hole can be terminated when the injection rate of grout material becomes
no more than 2 litres per minute for 20 minutes under specified pressure.

When the pressure for grouting keeps stable and injection rate decreases gradually, or
the injection rate keeps stable and the pressure increasing gradually, the ratio of
water/cement should not be changed.
Change in the thickness of grout and decrease/increase in pressure will be subject to

increase and decrease in inflow of the grout material.
The grouting methodology summaried below
1. Drilling of 40-75mm diameter hole to required length and inclination as per the
site condition.
2. The ascending method involves the advancement of the hole to full depth in one
drilling operation, followed by washing the complete length of the hole in one
washing operation.
3. The length of the hole is divided into 1.5m stages. The packer will be locked at
1.5m in the hole and release the grout in hole under specific pressure. The pressure
of grout will be maintained according to the rock condition.
4. Packer being moved to the next higher 1.5m stage after grouting has been
completed in the prior stage and the stage reached to the refusal pressure.

5. The various items of drilling, washing, water testing, and grouting equipment are
mobilized to the hole only one time.
6. The grouting machine will not be kept more than 25 meters away from the hole
being grouted.
Drawings
The proposed drawings are attached under Annex - 3.1
b. BACKFILL GROUTING WITHIN THE TUNNEL

Excavated rock surfaces are generally uneven. Hence, open spaces in the shape of
small cavities remain behind the concrete lining. It is also common practice that on the
back of the concrete lining, the honeycombing and open spaces/voids due to
movement/slipping/segregation of the mix design get develop.
This phenomenon is more valid at the central part of the crown of the tunnel and areas
containing cavities on the side wall. Such areas are undesirable to exist. These
voids/gevoids need to be filled with grout so as to save and protect the tunnel structure.
Backfill grouting reduces permeability around the tunnel also helps in minimising
corrosion in the concrete lining.
The methodolgy to be adopted for the backfill grouting will remain the same as that for
the contact grouting however the depth of holes will be increased by about 15cm
beyond the contact grouting holes depth or to a depth when the rock wall of the outer
shell is reached.
Drawings
c. Contact Grouting within the Tunnel
Objectives:
Underground structures have two shells; (a) the inner concrete / steel lining that
provide for smooth passage for water from the reservoir to the powerhouse and (b) the
outer shell of excavated structure of tunnel which provide space for construction of the
inner shell.
The outer shell passes through strata consisting of rocks of different lithologies and
varying physical characteristics. Conventional type of excavations, involving drilling and
blasting never leaves a smooth surface behind. Similarly the concrete emplaced for
construction of the inner shell cannot fill the uneven surface of the outer shell
completely.

There always occur open spaces in between the two shells of the tunnel structure. It is
essentially required to fill the gap between the two shells. The open spaces are bound
to serve as channels for seepage water and as voids for permeating water. The water
may ultimately cause damage to the inner shell.
The gap is filled by contact grouting which prolongs the life of the inner shell. It also
consolidates the inward surface of the outer shell. The contact grouting forms an anti-
seepage membrane whereby the routes of the seepage water is diverted away from
the inner shell. The grouting, between the inner and outer shells is internationally
termed as contact grouting.
Methodology:
Contact grouting will be conducted subsequently to the concrete lining of the tunnel. It
has been experienced that a thin line is left in between the concrete lining and the rock
wall. The cement concrete also develops open spaces all along the outer boundary of
the concrete lining of tunnel which work as paths for incoming water from rock wall. In
order to stop water, this thin but almost continues space all around the tunnel lining is
sealed by contact grouting.
The thickness of the concrete lining of Karora HPP tunnel is 23cm. for the purpose of
grouting, 23cm deep holes will be drilled through concrete lining and temporary support
structure as per the drawing shown in the annex - 3.3. Through which the grout
material will be injected to fill the empty annulus.
Drawings
d. Placement of Geomembrane
Normally the undesired leakages of water gets controlled by consolidation grouting in
fractured strata. However use of geomembrane become necessary in diverting / routing
of dripping water so that the concrete tunnel lining is saved from future demages. Most
of the ophiolitic rocks e.g gabbros and associated matel bearing rocks in the tunnel
are sulphide bearing. These tend to create acidic conditions. Such conditions are
injurious to steel and cement structures in the tunnel in the long run.
Geomembrane will be fastened to the excavated rock surface through widely spaced
wire mesh. The membrane sheets are avaliable in about one meter wide sheets of
different length. These are binded to one another by epoxy glue. Dripping water will be
collected/ routed to particular points and finally brought into the main water conduit/
tunnel or then to the dranige system of the tunnel.
It is important to mention here that, though in small quantity, the dripping water in long
terms add to the outer pressure of the tunnel. It is required that the outer and inner
pressure of the tunnel must remain in equilibrium. Once blocked the water can find its
natural pathes outwards of the water-conduit and avoid to enter the bed of the tunnel

so as not to exert extra pressure on the bed. On the contrary the slow but continuous
increase in this pressure ultimately decomposition of the concrete structure.
Rock grouting through consolidation grouting and application of geomemrance save

the tunnel structure from expected demages that occur with the passage of time.
e. TREATMENT OF THE EXTREME POOR ROCK ZONE IN THE TUNNEL

Two alternatives are suggested as under:
i. TREATMENT BY STRENGHTING OF THE CONCRETE LINING SUITING WORST

STRATA CONDITIONS
It has been stated/reported time and again that the Karora tunnel is unique from
geological point of view, especially for its location in “mélange Zone” of two tectonic
plates and therefore essentially requires special Rock support measures.
Keeping the above in view it is earnestly recommended that strong rigid Rock Support
measures be got designed to cater for worst conditions. In engineering works,
reinforced concrete is believed to be strong, rigid and durable construction material.
Drawing:
The proposed drawings are placed at Annex - 3.4
ii. INSTALLATION OF STEEL LINER

The 3.D geological mapping and Rock categorization of the tunnel has revealed that
various stretches of the tunnel comprise extreme poor strata. There areas are detailed
below;
a. Inlet Side: Total Length
i. RD 400-470
ii. RD 490-510 145 meters
iii. RD 755- 810
b. Outlet Side:
i. RD 75-110
ii. RD 485-540 90 Meters
c. Grand Total 235 meters
These poor zones were provided strong rock support during excavation; e.g. at inlet
side Lattice girders and solid steel arches, duly fastened to one another through 25-
35mm thick steel bars, properly rock bolted and thickly shotcreted, were installed at RD
417—431 and RD 760—780. at respective dates of 2nd March.2017to 14th May 2017
and 2nd March 2018—28th March 2018.
Convergence ranging between 0.2 m to 0.7m has been noted up till now. This rate of
deformation is undesirable.

In view of the above it becomes unavoidable to remove the deformed support

measures and install/enhanced rock support measure. The liner to be installed will
meet the requirements of ASTM standard A-36. Keeping in view the size of the water
conduit of the KHPP pressure tunnel with its 2.6 meters dia and the exerting pressure
of the weak zones and the convergence rate as stated above, the following parameters
are suggested.
Size of steel plate per shell of liner
a. Length = 8.3 meters
b. Width = 1.5 meters
c. Thickness = 14 millimeters
d. Stiffener /collar to the shell at 0.6 meters interval and about 250mm away from
the main welding joint of two adjoining shells.
The bed level of the liner will remain the same as the level of the concreted bed.
The liner will be concrete-embedded.
4. ABSTRACT OF COST:
Summary of the cost is being presented over here. The details of the cost are
being referred to attached Annex-1.
a. Abstract of Cost with RCC Lining
ABSTRACT OF COST
PROPOSAL NO - 1 Annex-1
S.no Description Unit Quantity Rate Amount Remarks
Drilling required for
A
grouting
Length of
Rate Analysis
Drilling for M
1.0 12,845.9 6,090.4 78,236,891.7 GHT 2
Grouting
Qty of Cement
B
required for grouting
Qty of Cement with Labour

2.0 Bag Bags 230,362.5 890.0 205,022,625.0 Cost
C Accelerator (Chemical) required for Grouting
Accelerator with Labour

Kg
3.0 Qty Required 1,036,631 165.0 171,044,156.3 Cost

D Geomembrane
with Labour
Geomembrane Sqm
4.0 4,265.0 953.0 4,064,545.0 Cost
RCC lining of Critical

E
Zone in Tunnel
Extra Rate Analysis

Cum
5.0 Excavation 795.9 7,788.9 6,199,254.7 GHT 1
RCC Lining Rate Analysis

Cum
6.0 Work 760.0 17,153.2 13,035,638.2 GHT 3
Form Work for Rate Analysis

Sqm
7.0 RCC Lining 2,487.5 2,292.0 5,701,292.7 GHT 5
Rate Analysis
Steel Ton
8.0 76.0 132,750.0 10,088,395.8 GHT 4
E Total (E)
35,024,581.4
Total
(A+B+C+D+E) 493,392,799
Overhead &
21%
Profit (21)% 493,392,799
Grand Total PKR

597,005,287
b. Abstract of Cost with Steel Lining
ABSTRACT OF COST
PROPOSAL NO - 2 Annex-1

S.no Description Unit Quantity Rate Amount Remarks

Drilling required for
A
grouting
Length of Drilling Rate Analysis

M
1.0 for Grouting 12,845.9 6,090.4 78,236,891.7 GHT 2
Qty of Cement required

B
for grouting
Qty of Cement with Labour

2.0 Bag Bags 230,362.5 890.0 205,022,625.0 Cost
C Accelerator (Chemical) required for Grouting
Accelerator Qty with Labour

Kg
3.0 Required 1,036,631 165.0 171,044,156.3 Cost
D Geomembrane
with Labour
Geomembrane Sqm
4.0 4,265.0 953.0 4,064,545.0 Cost
E Steel Lining for Critical zone in Tunnel
Rate Analysis
Steel Lining KG
5.0 327,685.2 491.0 160,893,443.8 GHT 6
E Total (E) 160,893,444

Total
(A+B+C+D+E)
619,261,662
Overhead &
Profit (21)%
21% 130,044,949
Grand Total PKR 749,306,611

5. ABSTRACT OF QUANTITIES:
The details of the Quantaties are being referred to attached Annex-2.

6. ROCK MASS CLASSIFICATION – ACTUAL VS FEASIBILITY COMPARISON:
Actual vs Feasibility comparison is being presented here as under. The graphical representation of rock mass
classification – Actual vs Feasibility Comparison is being referred to attached Annex-C.
KARORA HYDRO POWER PROJECT 11.8 MW DISTRICT SHANGLA

ROCK MASS CLASSIFICATION-..Actual vs Feasibility Status
Rock Categorization Along the Tunnel Route (As Per Rock Categorization Along the Tunnel Route (Final Feasibility
Actual) Report Chapter-3)
S Chain age Rock Chain age Rock Rock
Rock Type Length Rock Type Length
No. From To Category From To Description Category
Poor to
Highly Jointed
1 0+00 0+30 30 Very
Granitic Gneiss
Poor
Highly Jointed
2 0+30 0+120 90 Fair
Granitic Gneiss
Highly Jointed
Granitic Gneiss, Poor to Massive, blocky,
3 Deformed Ultrabasic, 0+120 0+240 120 Very Granite
0+000 0+300 300 strong, tunnel Good
Gneiss
Diorite, Amphibolite Poor drive with dip
Quartz-PG Intrusions
Diorite, Quartz-PG
4 0+240 0+265 25 Fair
Intrusion
Deformed Sheared Poor to
5 Ultrabasic, Granitic 0+265 0+300 35 Very
Gneiss, Diorite Poor
Granitic Gneiss, Tectonized Closely jointed, Poor to V.
6 0+300 0+335 35 Fair 0+300 0+600 300
Diorite Zone moderately to poor
PROPOSAL FOR CONSOLIDATION, BACKFILL AND CONTACT GROUTING, EMPLACEMENT OF GEOMEMBRANE & STEEL LINER
Highly Jointed and highly fractured (50 % of

Sheared Granitic Poor to and sheared the length
with doloritic i.e. 150 m
7 Gniess, Deformed 0+335 0+410 75 Very
dykes/ sills. is poor
Ultrabasic, Quartz- Poor and
PG Intrusion remaining
Intensely Sheared 50 % i.e.
and Deformed 150 m is
Ultrabasic V. poor)
(Pyroxinite, Extremely
8 0+410 0+520 110
Hornblendite Poor
peridodite,
Serpentinite, Dunite,
Mylonite).
Moderately Jointed
Granitic Gniess,
Sheared Ultrabasic
(Pyroxinite, Fair to
9 0+520 0+580 60
Hornblendite Poor
peridodite,
Mylonite).
10 Granitic Gniess 0+580 0+600 20 Fair
Poor to
Highly jointed and
11 0+600 0+615 15 Very
Sheared Ultrabasic
Poor
Massive, blocky,
Granitic Gniess, Granite
12 0+615 0+675 60 Fair 0+600 1+150 550 strong, tunnel Good
Quratz-PG Intrusions Gneiss
drive with dip
Poor to
Highly jointed and
13 0+675 0+685 10 Very
Sheared Ultrabasic
Poor


Highly Jointed
Granitic Gniess,
Sheared and
Deformed
Very to
Ultrabasics
15 0+750 0+810 60 Extremely
(Pyroxinite,
Poor
Hornblendite
peridodite,
Mylonite).
Granitic Gniess,
16 0+810 0+835 25 Fair
Amphibolite, Gabbro
Granitic Gniess,
17 Ultrabasics, Quartz- 0+835 0+890 55 Fair
PG Intrusion
18 Gabbro 0+890 1+055 165 Good
Highly schistose,
moderately to
closely jointed
Graphitic
1+150 1+200 50 with highly V. Poor
Schist
sheared zones,
tunnel drive with
dip
Blocky to closely
Granitic Gniess, jointed,
Granite
19 Ultrabasics rocks, 1+252 1+427 175 Good 1+200 1+400 200 fractured, tunnel Fair
Gneiss
Quartz-PG Intrusions drive both with
and against dip

Highly schistose,
moderately to
Moderately Jointed closely jointed
Graphitic
20 Granitic Gniess, 1+427 1+433 6 Fair 1+400 1+450 50 with highly V. Poor
Schist
Quartz-PG Intrusion sheared zones,
tunnel drive
against dip
Moderately Jointed
21 Granitic Gniess, 1+433 1+588 155 Good
Quartz-PG Intrusion
Sheared Ultrabasics
Poor to
22 rocks, Quartz-PG 1+588 1+592 4
Fair
Intrusions
Granitic Gniess, Massive, blocky,
23 1+592 1+607 15 Fair Granite
Quartz-PG Intrusions 1+450 2+300 850 strong, tunnel Good
Gneiss
Granitic Gniess, drive against dip
Ultrabasics rocks,
24 Recrystallization 1+607 1+717 110 Fair
Limestone, Quartz-
PG Intrusions
Granitic Gniess, Fair to
25 1+717 1+768 51
Quartz-PG Intrusions Good
26 1+768 1+774 6
Quartz-PG Intrusions Poor
Granitic Gniess,
27 1+774 1+801 27 Fair


28 1+801 1+901 100
Amphibolite, Diorite Good
Granitic Gniess, Poor to
29 1+901 1+936 35
Amphibolite, Diorite Fair
Granitic Gniess,
30 1+936 2+046 110 Fair
Ultrabaics
Deformed and Highly
Sheared Ultrabasics, Poor to
31 Hornblendite, 2+046 2+086 40 Very
Serpentinites, Qz-PG Poor
Intuarsion
Granitic Gniess,
32 2+086 2+266 180 Fair
Ultrabasics Rocks
highly ro moderately
Jointed Granitic Fair to
33 2+266 2+306 40
Gniess, Deformed Poor
Ultrabasics Rocks
Fair to
34 Granitic Gniess 2+306 2+316 10
Poor
Fair to
36 Granitic Gniess 2+346 2+356 10
Poor
Blocky to closely
Granite jointed,
Highly Jointed 2+300 2+500 200 Fair
Gneiss fractured, tunnel
Granitic Gniess, drive against dip
38 2+431 2+466 35 Poor
Dioritic Dykes,
Highly Jointed and Poor to
39 Sheared Granitic 2+466 2+516 50 Very
Gniess Poor

Highly schistose,
Highly jointed moderately to
Granitic Gniess, Poor to closely jointed
Graphitic
40 Deformed Ultrabasic 2+516 2+546 30 Very 2+500 2+600 100 with highly V. Poor
Schist
Rocks, Quartz-PG Poor sheared zones,
Intrusion tunnel drive
against dip
Highly Sheared Poor to
41 Ultrabasic Rocks, 2+546 2+681 135 Very
Quartz-PG Intrusion Poor
Highly Sheared
Fair to
42 Ultrabasic Rocks, 2+681 2+696 15
Poor
Quartz-PG Intrusion
Sheared Ultrabasics
43 rocks, Quartz-PG 2+696 2+716 20 Fair
Intrusions
Sheared Ultrabasics
Blocky to closely
44 rocks, Quartz-PG 2+716 2+771 55 Fair Granite
2+600 2+980 380 jointed, Fair
Intrusions Gneiss
fractured,
Deformed and Highly
Sheared Ultrabasics,
Extremely
45 Hornblendite, 2+771 2+806 35
Poor
Serpentinites, Qz-PG
Intuarsion
Deformed and Highly
Extremely
46 Hornblendite, 2+806 2+831 25
Poor
Intuarsion

Deformed and Highly

Extremely
47 Hornblendite, 2+831 2+861 30
Poor
Intuarsion
Deformed and Highly
Sheared Ultrabasic,
Extremely
48 Hornblendite, 2+861 2+931 70
Poor
Intuarsion
Deformed and Highly
Sheared Ultrabasics, Extremely
49 2+931 2+956 25
Hornblendite, Poor
Serpentinites
Deformed and Highly
Sheared Ultrabasic
Extremely
50 Rocks, Highly jointed 2+956 2980 24
Poor
and Sheared Granitic
Gniess

PROPOSAL FOR CONSOLIDATION, BACKFILL AND CONTACT GROUTING,
EMPLACEMENT OF GEOMEMBRANE & STEEL LINER OR ENHANCED RCC LINING FOR
TUNNEL
7. GEOLOGICAL MAPPING FOR TUNNEL INLET – SUPPORTING

DOCUMENT:
Geological mapping for tunnel in let duly verified from MC is being referred to
attached Annex-4.1.
8. GEOLOGICAL MAPPING FOR TUNNEL OUTLET – SUPPORTING

DOCUMENT:
Geological mapping for tunnel out let duly verified from MC is being referred to
attached Annex-4.2
9. CONCLUSION:
Since the stability of the tunnel is most important therefore, our recommendation is to
get the decision for such proposal at earliest. Upon acceptance of such proposal, detail
drawings/design and study may be submitted for your kind approval along with the
variation order.
10. LIST OF ATTACHMENT
KARORA HYDRO POWER PROJECT 11.8 MW, DISTRICT SHANGLA

PUROPOSAL FOR CONSOLIDATION GROUTING, CONTACT/BACK FILL GROUTING AND RCC LINING WORK
OF CRITICAL ZONE IN TUNNEL
LSIT OF ATTCHEMENT
SR
CONTENTS ANNEXES
NO.
ABSTRACT OF
1 ANNEX-1
COST
I WITH STEEL LINER ANNEX - 1.1
II WITH RCC LINING ANNEX - 1.2
ABSTRAT OF
2 ANNEX-2
QUANTATIES
I WITH STEEL LINER ANNEX - 2.1
II WITH RCC LINING ANNEX - 2.2

PROPOSAL FOR CONSOLIDATION, BACKFILL AND CONTACT GROUTING,
EMPLACEMENT OF GEOMEMBRANE & STEEL LINER OR ENHANCED RCC LINING FOR
TUNNEL
PROPOSAL
3 ANNEX-3
DRAWINGS
CONSOLIDATION
I ANNEX-3.1
GROUTING DRAWINGS
BACK FILL GROUTING
II ANNEX-3.2
DRAWINGS
CONTACT GROUTING
III ANNEX-3.3
DRAWINGS
RCC LINING FOR CRITICAL
IV ANNEX-3.4
ZONE IN TUNNEL
GEOLOGICAL
4 ANNEX-4
MAPPING
I TUNNEL INLET SITE ANNEX-4.1
II TUNNEL OUTLET SITE ANNEX-4.2
CNTRACT
5 ANNEX-5
REQUIRMENT
TUNNEL IFC
6 ANNEX-6
DRAWINGS

Proposal for Tunnel Stabilization

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Proposal for Tunnel Stabilization

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ROCK STABILITY OF TUNNEL

PROPOSAL FOR CONSOLIDATION, BACKFILL AND CONTACT

GRC JOINT VENTURE

December 08, 2018 Page 1 of 21

The success of grouting, speacialy in the present situations is estimated to be about

In addition to the Consolidation Grouting and installation of Geomembrane, Contact and

2. WHY WE NEED TO OPT. THIS PROPOSAL?

December 08, 2018 Page 2 of 21

8. The repeated below-outs of slush of heterogeneous lithologies, e.g areas onward

3. ELEMENTS FOR ROCK MASS STABILITY:

a. Consolidation Grouting within the Tunnel

 Providing support to poor quality rocks determined through Internationally

December 08, 2018 Page 3 of 21

consolidation grouting is conducted. Consolidation is also a rock strengthening

Ascending stage grouting method with Mechanical/Pneumatic packers will be

December 08, 2018 Page 4 of 21

Change in the thickness of grout and decrease/increase in pressure will be subject to

The grouting methodology summaried below

December 08, 2018 Page 5 of 21

b. BACKFILL GROUTING WITHIN THE TUNNEL

c. Contact Grouting within the Tunnel

December 08, 2018 Page 6 of 21

December 08, 2018 Page 7 of 21

Rock grouting through consolidation grouting and application of geomemrance save

e. TREATMENT OF THE EXTREME POOR ROCK ZONE IN THE TUNNEL

i. TREATMENT BY STRENGHTING OF THE CONCRETE LINING SUITING WORST

ii. INSTALLATION OF STEEL LINER

c. Grand Total 235 meters

December 08, 2018 Page 8 of 21

In view of the above it becomes unavoidable to remove the deformed support

a. Abstract of Cost with RCC Lining

Qty of Cement with Labour

C Accelerator (Chemical) required for Grouting

Accelerator with Labour

December 08, 2018 Page 9 of 21

RCC lining of Critical

Extra Rate Analysis

RCC Lining Rate Analysis

Form Work for Rate Analysis

Grand Total PKR

December 08, 2018 Page 10 of 21

S.no Description Unit Quantity Rate Amount Remarks

Length of Drilling Rate Analysis

Qty of Cement required

Qty of Cement with Labour

C Accelerator (Chemical) required for Grouting

Accelerator Qty with Labour

E Steel Lining for Critical zone in Tunnel

E Total (E) 160,893,444

Grand Total PKR 749,306,611

December 08, 2018 Page 11 of 21

December 08, 2018 Page 12 of 21

KARORA HYDRO POWER PROJECT 11.8 MW DISTRICT SHANGLA

Highly Jointed and highly fractured (50 % of

December 08, 2018 Page 14 of 21

14 Granitic Gniess 0+685 0+750 65 Fair

December 08, 2018 Page 15 of 21

December 08, 2018 Page 16 of 21

Granitic Gniess, Fair to

December 08, 2018 Page 17 of 21

December 08, 2018 Page 18 of 21

Deformed and Highly

December 08, 2018 Page 19 of 21