Universita di Roma “Sapienza” Dipartimento di Ingegneria Strutturale e Geotecnica Effectiveness study of foaming agent developed by SIKA for tunnelling with TBM-EPB technology Synthesis of the laboratory activities and results dott. ing. odsepSudsos prof. ing\Salvatare Miliziano uw December 2017DInARTIMENTO DIINGEGNERIA ae G> GEEG SAPIENZA QD amaress 1 Introduction 2 Preliminary evaluation on the product and foam generation tests 2.1 Foaming product tested and its physical characteristics 2.2. Laboratory foam generation and definitions... 2.3 Halflife tests. 3. Sample of soil used... 4 Laboratory tests performed on samples of conditioned soil 41 Slump test 5 Results obtained suns Research project DISG - SIKA: Synthesis of the laboratory activities Pag. 2@ wna €3 GEEG 1 Introduction ‘This document is the final report of the effectiveness study on the foaming agents developed by SIKA for tunnel boring machines (TBM) and earth pressure balance technology (EPB) applications, and in particular that proposed for coarse grained soils. The study includes an experimental activity, performed in the Geotechnical Laboratory of the Department (DISG) that is equipped to develop specific tests to verify the effectiveness of foaming agents used for mechanized tunneling, Laboratory tests were performed to verify the effectiveness of the product in modifying the features of the fine and coarse-grained soils, to make them suitable for the excavation with TBM- EPB. 2 Prelit lary evaluation on the product and foam generation tests 2.1 Foaming product tested and its physical characteristics ‘The product used for the experimental activity is: © SIKA Foam TBM 101 FB. The product is currently used for TBM applications, it is readily soluble in water and has characteristics (viscosity and sp. it) suitable for use in injection systems like those installed on TBMs. Figure 1 shows the product and in tables 1 and 2 the results of some preliminary evaluations on the physical characteristics are listed. SIKA Foam TBM-A01-F8 Figure 1 - Sample of foam generated using the foaming agents. ‘The specific weights of the product, listed in Table 1, fall within the commonly measured range of values for foaming products used for mechanized tunnel excavation performed with EPB technology. en i ES Research project DISG - SIKA: Synthesis of the laboratory activities Pag. 3Diragristento pr INckeneata 'STROTTURALL F GEOTIENICA SAPIENZA =o GEEG Tnnvensita D1 ROMA, Table 1 ~Specific weight of the products. SIKA Foam TBM 101 FB (e/em?) 1.064 40.001 ‘The same considerations can be made for the viscosity value, listed in Table 2, which is in the range of values commonly measured using the Marsh cone. Table 2 — Results of the viscosity (marsh cone) tests on the products. SIKA Foam TBM 101 FB (s) 37/37/37 2.2 Laboratory foam generation and definitions The quality and the reproducibility of testing rely on the quality of the foam produced for the tests. In poorly produced foam the bubbles combine and break more rapidly, consequently the foam quality varies from test to test. Generating foam with a laboratory foam generation system equipped with real components directly from the plant installed inside a TBM machine, assures that the quality of the foam will be the same each time and, moreover, it will be the same as that used in tunneling. The laboratory foam generation system is described by the following Figures 2 and 3. airline foaming agent ine foam —! T water tine lyre (itmeedes) Figure 2 - Laboratory foam generation system functioning scheme. Research project DISG - SIKA: Synthesis of the laboratory activities Pag.4DiPAKTIENTO DLINGEENERIA STRUTTURALE F GEOTEENICA Ga SAPIENZA €3 GEEG TyiverstrA Dr ROMA, recording cabinet foaming agent pump & power unit 1 polymer ine \\ Ht liquid tne (ater + agents) epheen i — foaming agent tank Figure 3 - Laboratory foam generation system, description. Pressure and flow of water and air and foaming agent can be controlled manually through pressure gauges and flow meters on the machine and their values can be changed in real time during foam generation; all operations are monitored through the Human Machine Interface, HMI (Figure 4). Figure 4 - Detail of HIMI (Human Machine Interface). a cnr nn Research project DISG - SIKA: Synthesis of the laboratory activities Pag.5Dirarrinsento uh SAPIENZA G3 GEEG Bavesrrs os Rowe QW mata The properties of the foam are described through some characteristic parameters listed below. Concentration Factor, Of m Cf = 100. m sol Where mag is the mass of foaming agent used and rsa is the mass of foaming solution. The concentration of foaming solution Cf is typically in the range 0.5 - 3.0 % but should follow/respect the manufacturer's recommendations. This concentration strongly depends on the amount of water injected or already present in the soil and also affects the activity and stability of the tunnel foam used. Foam Expansion Ratio, FER V, FER= V, ‘ot where Veis the volume of foam (generated) and Vso is the volume of foaming solution, FER should be commonly in the range of value of 5 - 30. The higher the FER, the drier a generated foam will be. Foam Injection Ratio, FIR y, FIR = 100 -—£ V, where V; is the volume of foam (injected to the front) and Vs is the volume of excavated soil. 2.3. Half-life tests For TBM-EPB applications, it is important to know the total period for which a foam would be stable in the foam-soil mixture in the working chamber and screw conveyor. Beyond this period the foam may collapse, causing loss of workability in the material to be excavated and an undesirable loss of the earth pressure balance. In general, the foam stability s a function of the size distribution of the bubbles and of the strength of the bubble wall, for this reason the bubble size should be as small and uniform as possible. Figures 5 and 6 show micro and macro scale pictures of the foam, that appears composed of bubbles small enough to ensure stability and quite homogeneous in the range of FER values tested. Research project DISG - SIKA: Synthesis of the laboratory activities Pag.6DIPARTIMENTO DLINGEGNERIA 'STRUTTURALL E GEOTECNICA SAPIENZA G3 GEEG teak Ko SD aes Figure 5 - Foam generated for the experimental tests (digital microscope view). Figure 6 - Foam generated for the experimental tests. As proposed by EFNARC, a laboratory test for the evaluation of the stability of the generated foam is the half-life test, which requires a specific apparatus consisting of a cylinder with a funnel lower basis and a graduated cylinder below to collect the liquid drained from the foam over time, as shown in Figure 7. To verify the stability of the foam generated using the foaming product supplied by SIKA, several halflife tests were performed; the results are shown in Figures 8 and 9. Research project DISG - SIKA: Synthesis of the laboratory activities Pag. 7DInARTIMENTO DL INGEGNERIA STRUTTURALE E GEOTHCNICA SAPIENZA G3 GEEG Dekasrxo hous QD iaawaea Figure 7 - Half-life test laboratory apparatus and photo of a performed test. ‘SIKA Foam 101 FB “eh te - EE l/s FER9-c120% Pen 10-c120% FER 12-c120% FER 4-c120% > ° 100 200 300 time (s) Figure 8 - Results of half-life tests performed on foam samples generated with SIKA foam 101 FB. ‘The increase in the half-life time and consequently the stability of the foam with the increase of FER and Cfis seen quite clearly. Research project DISG - SIKA: Synthesis of the laboratory activities Pag.8DirantMento or INcrGNERA SAPIENZA €3 GEEG drained liquid (ml) a leesnrararerc]| alee saa eet certain o- 2 Ln ° 50 100 150200250 time (s) Figure 9 - Results of half-life tests performed on foam samples generated with SIKA foam 101 FB. The evaluations and the half-life tests carried out and described in this paragraph allowed to verify that the foam generated with the product supplied by SIKA has the appropriate characteristics to be profitably used in the mechanized excavation; in order to more accurately verify the stability of the generated foam, it will however be necessary to perform laboratory tests specifically designed as the half-life test in a pressurized environment. 3 Soil sample Anatural soil samples available in the laboratory was selected to be used in the experimental activity. To verify the effectiveness of the product SIKA Foam TBM 101 FB in proper conditioning coarse soils was selected a limit case represented by a gravelly sand, named Soil 1 (figure 10). In figure 11 is presented the grain size distribution curves of the selected soil sample. Figure 10 - Dried soil samples S1 (a) selected for the experimental tests. Research project DISG - SIKA: Synthesis of the laboratory activities Pag.9DIPARTIMENTO DLINGEGNERIA SSTRUTTURALE E GEOTYENICA SAPIENZA GS GEEG Teena bout QD amass clay silt [sand yravel oe a ] THM TI TTT ‘cobb pass. (%) 0.08, 2 60 diameter (mm) Figure 11 - Grain size curves for the soil sample selected for the experimental tests. 4 Laboratory tests performed on samples of conditioned soil 4.1. Slump test The slump test measures the effect of the injection of water and foam on the “consistency” of the soil, and it is usually carried out to individuate the best dosages required for digging purposes. This test is usually performed for coarse-grained soils; for fine-grained soil the slump test is performed to measure the effect of the lumps while, for homogeneous samples, a similar test has been developed, using a flow table. The test apparatuses are represented in the Figure 12. Figure 12 - Abrams cone test apparatus and Flow table test apparatus. Research project DISG - SIKA: Synthesis of the laboratory activities Pag. 10@ wes €3 SEE 5 Results obtained To verify the possibility of obtaining the right consistency in coarse grained soil using the generated foam, some soil samples of the coarse-grained soil S1 were prepared, all having the same characteristics, and they have been conditioned mixing it (2 minutes) with water and foam in different dosages. After some preliminary tests, it was possible to obtain an optimal consistency in the soil (slump measure between 10-20 cm) by using a FIR 40% (Figure 13). Once the consistency was considered acceptable, the amount of injected foam was modified in order to check the range of values for which the consistency of the soil was still acceptable for TBM-EPB application. Figures 13, 14, 15 and 17 show some photos of the performed tests for which the optimal consistency was reached for different values of soil samples water content, w, and FIR used. In Figure 16 is presented a case for which the consistency can be considered borderline, since the conditioned soil sample shows some signs of an excessive liquidity as it can be noted from the excess water that starts to flow out at the base of the slump. In Table 3 a list of slump tests on soil sample S1, conditioned with foam generated ‘TBM 101 FB dosed using a Cf of 2.0% and a FER 12, that provided good results is reported. SIKA Foam Table 3 - Slump test and measurements performed, Test Code wo Ca FER FIR Slump Wen O (%) (%) bc) (6) (cm) S01 60 | 20 20 © ««400~=«SS 7G s-02 70 20 1220 300 «110 82 $03 90 20 120 200 «140-10 5-04 90 20 12200 350-200 4. $05 too 20 20 200,140 11,7 Sika Foam T8H 404 FB Guan pees week FIR. gon Figure 13 - Mixing test result (test $-01). ————————— Research project DISG - SIKA: Synthesis of the laboratory activities Pag. 11DIPAKTIMENTO DI INGEGNERIA STRUTTURALL F GEOTTENICA SAPIENZA GEEG Taivenstra vr Roma =araereer SIKA Foan TBH AOA FB Ga2% PER MD wth FIR-30% Figure 14 - Mixing test result (test S-02). SIKA Foah TSH 404 FB kA Foam TSH 404 FB quam ree wee FIR. 85: Figure 16 - Mixing test result (test 5-04). Research project DISG - SIKA: Synthesis of the laboratory activities Pag. 12DIPARTIAENTO DI ING SAPIENZA Tivweestra'Dr ROMA SIkA foan TSH 404 FB Gam FERAL Figure 17 - Mixing test result (test $-05). On the basis of the results of the tests performed on soil samples $1 we can conclude that with limited amounts of foam (FIR between 20% and 40%) it is possible to change the consistency of a coarse- grained soil sample until it reaches the optimum consistency for the excavation with TBM-EPB technology. Further laboratory tests can be carried out to define the best dosage also as a function of the ability of the injected foam of reducing the wear measured on the digging tools. Conclusions and Future developments ‘At the end of the experimental activities described in this document it was achieved a good knowledge, although preliminary, about the behaviour of the tested product. It is believed that the information acquired are sufficient to provide a general idea of the effectiveness of the product and it seems clear that the product is adequate for mechanized ‘excavation with TBM EPB technology. With reference to the performed tests, it is possible to list few conclusion: - the product SIKA Foam TBM 101 FB has physical characteristics suitable for use in the injection plants commonly installed on TBMs; ~ it is possible to confer to the samples of coarse grained soil a consistency suitable for the excavation process through the use of the product SIKA Foam TBM 101 FB; the proper consistency can be reached even in presence of a relatively high water content reducing the FIR value; To explore more specific aspects of products behavior it will be possible to deepen the study of the items listed below: ~ verify the effectiveness of the foaming product in coarse grained soil conditioning developing tests more specific as the abrasion test and the permeability test; ee Research project DISG - SIKA: Synthesis of the laboratory activities Pag, 13bu Sees 5 GEEG - to verify the environmental impact of the product developing and performing specific chemical and eco-toxicological tests. Finally, it should be specified that the laboratory activities describe document were aimed at testing the general effectiveness of the product in proper conditioning some laboratory samples of natural soil and that therefore, in the case of applications in a specific project, the dosages of water and foam and the characteristic parameters of the conditioning have to be determined by specific tests carried out using the soil coming from the real site. rr Research project DISG - SIKA: Synthesis of the laboratory activities Pag. 14