Effective Grouting Materials for Tunneling through

Unconsolidated Ground

Shingo Wakita1, Kensuke Date1, Takuji Yamamoto1, Hiroshi Yanagisawa2, Naoki Uesugi3
1
Kajima Technical Research Institute, Tokyo, Japan
2
Kajima Corporation, Yokohama, Japan
3
Road Bureau, City of Yokohama, Japan

ABSTRACT

With the increasing use of NATM in urban areas, numerous types of forepoling have been adopted to
reduce surface settlement or reinforce a cutting face. Actual ground is, however, heterogeneous, and
accordingly grouting materials are not injected as adequately as expected at the design stage. Grouting
consequently produces only inadequate reinforcing effects in many cases. A new grouting method has
been developed which allows the use of different grouting materials, according to the change in the
ground conditions. The grouting materials associated with this method are superior to conventional
materials in having good penetration into dense sandy ground and early development of strength. The
method’s superiority has been verified through injection tests and field use.

1. INTRODUCTION

Generally, urban tunnels are exposed to severe excavation conditions e.g. in unconsolidated sandy
layers, with a thin earth cover, right under existing structures and near underground structures.
However, cost pressures and handling of diverse cross sections have been recently required, and
accordingly NATM has been introduced under such conditions.
The fact that NATM has been adopted under such conditions owes greatly to the development of
auxiliary methods. In particular, forepoling has been frequently used to stabilize the ground around the
cutting face, and to control the settlement of ground surface. This method involves the driving of pipes
and the injecting of grouting materials into the ground ahead of face prior to excavation. Among many
forepoling methods, the long-forepoling method, being considered to be the most effective for the
control of ground deformation, has been most frequently adapted. Another forepoling method (Figure
1) has been developed that is more effective for controlling ground deformation and is less costly than

Long-forepoling method New forepoling method

12.5m 5.5m
3.5m 3.5m

5 degrees 14 degrees

Specification of steel pipes Specification of steel pipes

- Diameter: 114.8mm Cutting - Diameter: 76.3mm Cutting
- Driven pitch: 450mm face - Driven pitch: 300mm face
- Driven angle: 5degrees - Driven angle: 14degrees
- 26 pipes per cross section - 38 pipes per cross section

Figure 1. Comparison between two forepoling methods

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the long-forepoling method. A design method for forepoling, based on the cylindrical shell theory, has
been used to verify the superiority of this new forepoling method.
In applying the new forepoling method, it has been found that the grouting materials are not always
injected radially and uniformly. In many cases of actual injection, the grouting material was only
injected within the inside of steel pipes or runs away, and, as a result, the ground was not improved
sufficiently. It is considered that this occurred for two reasons: one is because the adopted material
was not appropriate for the ground to be improved, and the other is because the ground conditions
changed as a tunnel proceeded. Consequently, it is necessary to prepare a few types of grouting
material to excavate ground safely, but it takes much time to change grouting materials. Moreover, all
grouting materials currently available have at least one disadvantage, for example, lack of penetration,
shortage of strength or adverse environmental effects.
In order to solve these problems, many mixing tests and in-situ injection tests have been carried out,
resulting in the development of a new grouting method. In this method, two types of grouting
materials are available, and can be changed in a short time according to the change of ground
condition. Both materials have the high penetrability and early development of strength. In this paper,
the outline of the method is given, followed by the result of injection tests and actual grouting work.

2. OUTLINE OF A NEW GROUTING METHOD

2.1 Requirements for grouting materials in forepoling

The soils in urban areas are generally classified into two major types according to the way grouting
materials are injected (Table 1). One is the sandy ground in which grout permeates into the voids
between sand particles (ground condition 1). The other is the clay or fissured ground where grout
splits or penetrates into cracks (ground condition 2). Therefore the requirements for grouting materials
vary according to the ground conditions. The requirements in ground condition 1 are good penetration
and a long gel time in order for grout to permeate into fine voids. To excavate soon after grouting,
grout should give a high early strength.
In ground condition 2, the objective of soil improvement is the increase of the bond strength by vein-
type grouting. The grouting material is required to have a high early strength. Because the grouting
materials are highly likely to run away, the gel time should be easily controllable. Furthermore, if
permeation grouting is possible as well as vein-type grouting, the ground can be reinforced further.
Thus, higher penetrability is desired.

Table 1. Classification of ground conditions into two types

Ground condition 1 Ground condition 2

Mode of injection

Permeation grouting Vein-type grouting

Soil Sandy ground Clay or fissured ground

-High permeability (permeable even in dense soil) -Early development of strength and cohesion
Requirements of grout material itself
-Long gel time for grout to permeate
for grouting material into fine voids -Easy-controllable gel time
-Early development of strength of solidified sand -High permeability

Tunnel excavation in urban areas often involves grouting right under houses or near the water-bearing
ground from which groundwater is withdrawn. Grouting materials should therefore be friendly to the
environment.

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One of the characteristics of tunneling in Japan is the change in geological conditions with the advance
of excavation. Consequently, a few types of grouting material are necessary to excavate the ground
safely, but it takes much time and cost to change grouting materials. In the selection of grouting
materials, ground conditions and their changes should be carefully identified.

2.2 Conventional grouting materials and their problems

In Japan, cement and urethane grouts have been used for grouting in forepoling, and sodium silicate
grout for waterproofing. A comparison among these types of grout is given in Table 2. Cement grout
is used more than any other type of grout for forepoling. But, it is a suspension grouting material, so it
does not permeate in dense sandy ground and it may run away into cracks because of unstable gel
time. Under such ground conditions, urethane grout has a superior overall capacity. In Japan, however,
urethane grout is not generally applied, in order to avoid damage to human health and prevent the
contamination of groundwater. The grout is adopted only in emergency e.g. in the case where the
settlement of ground surface is of concern. Sodium silicate grout has not been used during tunnel
excavation because it has been intended for waterproofing, so it has a relatively weak strength. Those
types of sodium silicate grout that develop relatively high strength have slow gel time, so they have
not been adopted in tunnel forepoling.

2.3 Development of a new grouting method

To solve the problems described in Section 2.2, a new grouting method has been developed. The
initial focus was placed on sodium silicate grout in view of the environmental issues and the cost.
Conventional sodium silicate grout, however, could not produce adequate strength, so an optimum mix
proportion of sodium silicate and hardeners was selected so as to develop strength early. Ground
conditions 1 and 2 are expected to be encountered irregularly as tunnel excavated. It has been decided
therefore to use either of two different types of substance B (hardeners) in addition to substance A
(Special sodium silicate grout) according to the ground condition. For substance B, the Solution-type
grout fit for ground condition 1 and the Suspension-type grout effective in ground condition 2 are
made available in this method. The approach is expected to prevent the loss of construction time
because of the use of multiple materials and enable grouting materials to be switched with the
minimum amount of work (only switch substance B).

Table 2. Comparison among three conventional grouting materials

Cement grout Urethane grout Sodium silicate grout
Viscosity : 50 to 150 mPa s Viscosity : 50 to 170 mPa s Viscosity : 5 to 10 mPa s
Permeability
Low *1 Medium *2 High
Compressive strength 2 2
0.5 to 1.0 N/mm 4.0 N/mm 0.1 N/mm2
of grout material itself
( in a day ) Medium High Low

Control of gel time 10 to 120 minutes *3 40 to 120 seconds A few seconds to a few minutes

Safety and
Small Great Small
environmental load

*1 Some grouting materials use superfine cement to compensate for the low permeability of ordinary
cement.
*2 The grout has a rapid rise time, so fracture grouting is likely to take place in dense sandy ground.
*3 Cement grout generally has unstable gel time.
The physical properties of materials used in this method are listed in Table 3. As shown in the table,
both grouting materials can develop strength early The solution-type grout develops a compressive
strength of solidified sand of 1.0 N/mm2 in a day, and Suspension-type grout develops a compressive
strength of the grout material itself of 0.5 N/mm2 in a day. Both grouting materials enable the control
of gel time by changing the amount of gel time controlling agent in substance B.

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3. COMPARATIVE GROUTING TESTS

In-situ and laboratory injection tests were conducted to verify the penetration of the two types of
grouting materials, the condition of completed columns of solidified soil, and to compare the materials
with conventional grouting materials.

3.1 Injection test for Solution-type grout

In-situ comparative injection tests were conducted using Solution-type grout and urethane grout in
dense sandy ground (ground condition 1). Six-meter steel pipes were driven on the cut surface of a
slope for grout injection. The sandy ground composed 37% of sand, 34% of silt and 29% of clay. The
specifications for injection are listed in Table 4. For Solution-type grout, injection pressure was held to
a low level of 0.1 to 0.15 MPa in every hole from the initial stage of injection. The design quantity of
Solution-type grout could be injected at a rate slightly higher than the level adopted in ordinary
chemical grouting (around 10 L/min). When urethane grout was injected, the maximum injection
pressure was double that for Solution-type grout.
Figure 2 shows the columns of solidified soil that were excavated one week after grouting. When
Solution-type grout was employed, solidified columns of mean diameter of 800 to 1400 mm were

Table 3. Physical properties of two types of grouting materials

Solution-type grout Suspension-type grout

Substance A Special sodium silicate grout

-Solution-type hardener -Suspension-type hardener
Substance B -Gel time controlling agent -Gel time controlling agent
-Water -Water
Compressive
More than 1.0 N/mm2 More than 0.5 N/mm2
Strength
for solidified sand for grout material itself
(in a day)
Higher permeability than that of
Permeability Permeable even in dense fine sand
highly permeable cement grout

8 to 45 minutes 4 to 10 minutes
Gel time
Can be reduced to approximately 3 minutes Can be reduced to approximately 30 seconds

Table 4. Specifications for in-site grout injection test

Desired diameter of
Actual quantity of grouting Rate of injection Injection pressure
solidified columns
Solution-type grout No. 1 1000 mm 760 L 12 ~ 16 L/min 0.4 ~ 0.55 MPa

Solution-type grout No. 2 1000 mm 760 L 16 L/min 0.4 ~ 0.55 MPa

Urethane grout 800 mm 200 kg 3 ~ 4 kg/min 0.5 ~ 1.2 MPa

constructed. On the other hand, urethane grout was injected by fracture grouting and failed to form
cylindrical columns of solidified soil. In short, permeation grouting of Solution-type grout was
possible while urethane grout was impossible. It was concluded that the new method can achieve
permeation grouting in dense sandy ground, forming an arch of reinforced soils using forepoling.

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 Solution-type grout Urethane grout

No.1 No.2
6m long

Figure 2. Comparison of completed columns of solidified soil

3.2 Injection test for Suspension-type grout

To compare Suspension-type grout with conventional

Soil tank
cement grout, injection tests were conducted using a large
soil tank. Figure 3 shows the test apparatus. The large
Plunger pump
soil tank was designed to enable two polyvinyl chloride
pipes to be installed horizontally at a spacing of 900 mm
to simulate injection forepoling. The ground model in the
tank was made by placing 15-cm-thick layers of silica
sand of a mean particle size of approximately 180 µm
and with a water content of 5% to obtain the designated
Flow meter unit weight (γd = 1.50 g/cm2). Injection pipes were buried
in the ground in advance. A rubber bag was placed on the
top cover of the soil tank to enable the application of
Figure 3. General view of test apparatus overburden pressure to reproduce a desired earth cover
thickness. Fixed quantities of grout were injected into the
ground by a plunger pump through 10-mm-diameter small holes punched in the polyvinyl chloride
pipes (a total of eight holes at a pitch of 30 cm in a staggered pattern with two holes in a cross
section). The bottom cover of the soil tank was removed one day after grout injection to simulate
excavation, and completed columns of solidified sand were checked. The specifications for the grout
injection test are listed in Table 5. The design quantities of both types of grout could be injected.
When injecting cement grout, injection pressure increased to 0.5 MPa, while injection of suspension-
type grout was completed with no increase in injection pressure. Figure 4 shows the comparison of
solidified columns that were excavated one day after grouting.

Table 5. Specifications for test injection

Desired diameter of Maximum injection
Actual quantity of grouting Mean rate of injection
solidified columns pressure
Suspension-type grout 600 mm 100 L 3.0 L/min 0.2 MPa
Conventional
600 mm 100 L 3.0 L/min 0.5 MPa
cement grout

Cylindrical column of solidified sand was confirmed when Suspension-type grout was applied. When
cement grout was injected, approximately 30-cm-square solidified masses collapsed one after another
at the start of excavation and only a column close to the polyvinyl chloride pipes was left in the end.
The collapse probably occurred because conventional cement grout failed to combine compacted
columns of solidified sand with polyvinyl chloride pipes or combine columns to one another. As a

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result of the test, Suspension-type grout was found to have high permeability and be applicable to
construct combined solidified columns. The grout is therefore expected to be effective for reinforcing
the ground.

4. APPLICATION OF THE NEW GROUTING

METHOD TO A CONSTRUCTION SITE
Suspension-type Conventional
grout cement grout 4.1 Outline of a tunneling work

The Mori branch route of the Kanjo-nigo highway

route was planned and constructed by Road Bureau,
City of Yokohama, to provide a link between the
Wangan route of Metropolitan Expressway and
National Highway Route No. 357, and the Kanjo-
nigo highway route for congestion mitigation in the
city. The route consists of elevated sections and a
Figure 4. Comparison of completed columns
tunnel section at the midpoint (Figure 5 and 6). A
of solidified sand
164-m tunnel of binocular section was excavated by
NATM in June 2000 through March 2003. The geologic profile at the tunneling site consists of
alternating of clay and sandy formations. The small earth cover has a thickness of 5 to 17 m. Several
houses were located right above the tunnel alignment. Measures were therefore required to control
ground surface settlement. The ground ahead of the cutting face was reinforced by such auxiliary
methods as the injection long steel pipe forepoling method and the base reinforcement method.

Mori branch route

(1,220m long)
Tunnel
[m]
60
(164m long) Wangan route of
50 Metropolitan Expressway
40 Kanjo-nigo
30 highway route
Keihin Electric Shiomidai-Hirado JR Negishi National Highway
Express Railway line railway line railway line Route No.357

Figure 5. Outline of Mori branch route

Direction of excavation

Figure 6. Tunnel along the Mori branch route and surrounding environment

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4.2 Adoption of the new grouting method at exit portals

Tunnel portals are vulnerable to slope failures, landslides, unsymmetrical earth pressures, insufficient
bearing capacity of soil, face collapses and ground surface settlements because they have a thin earth
cover, and are constructed in geological materials such as talus deposits and weathered rocks. The exit
portal of the Mori branch route was designated as a steep slope failure hazard area because of past
slope failures. Ground surface settlements or slope failures upon the completion of tunnel excavation
were of concern. Reinforcing measures were therefore required at the completion of construction, and
pipe roofing was planned. However the construction yard was narrow and the road width was too
small for delivering heavy equipment. So it was impossible to apply such reinforcing measures as pipe
roofing and soil improvement from the ground surface.
As a means of reinforcement from inside the
tunnel, constructing an arch of reinforced soils
ntal inclinometers
Positions of horizo using the forepoling method, which was employed
placement
for monitoring dis Steel pipe length in ordinary sections, was planned. Figure 7 shows
1 2 3 4 5 6
6.5 m the drawing of the plan. A complex sequence of
7.5 m clay, silt, mudstone and sand formations existed at
Steel 8.5 m the portals. When conventional cement grout was
pipes used, cement grout was expected to run through
10.0 m
Cutting the cracks or voids. The use of urethane grout was
2m excavation
Face
SL
not recommended in view of the existence of
4m excavation private houses in the vicinity and environmental
impact. Grouting materials that could be injected in
limited grout zones under complicated ground
Figure 7. Positions of steel pipes and conditions were required, and the new grouting
horizontal inclinometers installed method was adopted.
near the exit portal of the tunnel

4.3 Results of excavation work

Figure 8 shows the geologic profile at the exit

portals of the tunnel. A fine sand and silt existed at
the exit portal of tunnel constructed in the first
phase (No.1 Tunnel), so Solution-type grout was
adopted. In the exit portal constructed in the
second phase (No.2 Tunnel), weathered mudstone
existed, so Suspension-type grout was employed.
The specifications for injection are shown in Table
6. To ensure safe excavation management,
No.1 Tunnel No.2 Tunnel horizontal inclinometers were attached to the
forepiles (Figure 7) to monitor the displacement of
Symbol Soil materials tunnel crown. The results of monitoring are shown
Ts Clay in Figure 9. As is obvious from the figure, the
Dt Silt with gravel displacement was held to a maximum of 12mm,
Dc-1 Tuffaceous clay
and below the control standards. Thus, excavation
Dsd-1 Fine sand with gravel
Dsd-2 Fine sand and silt was completed safely. Each time a tunnel support
Kct-w Weathered mudstone system was established, the improved area ahead
Kct Mudstone of the cutting face was monitored, and it was
Figure 8. Geologic profile at the exit confirmed that the grouting material penetrated
portals of the tunnel fully around the steel pipes and that an arch of
improved soil was formed.

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Table 6. Injection specifications
Grouting material Design quantity Desired diameter of
Construction section Rate of injection Condition for termination
used in the work of grouting solidified columns
Steel pipe length = l Design quantity of
No.1 Tunnel Solution-type grout l = 10.0 m 441 L 16 L / min grouting
l = 8.5 m 355 L 450 mm or
l = 7.5 m 298 L initial injection pressure
No.2 Tunnel Suspension-type grout 16 L / min
l = 6.5 m 241 L +0.3 MPa

At a point where excavation progressed 2 m into the tunnel

At a point where excavation progressed 4 m into the tunnel
At the point of completion of tunnel excavation

Numbers of horizontal inclinometers Numbers of horizontal inclinometers

1 2 3 4 5 6 1 2 3 4 5 6
horizontal inclinometers

0 0
Displacement of

-3 -3
[mm]

-6 -6
-9 -9
-12 -12
-15 -15
No.1 Tunnel No.2 Tunnel
Figure 9. Results of measurement with horizontal inclinometers

5. CONCLUSIONS

Forepoling has frequently been applied to the tunnel excavation by NATM in urban areas. However,
actual ground is not homogeneous, and thereby some grouting materials are not injected or run away,
and, consequently, grouting produces only inadequate reinforcing effects. A new grouting method has
been developed, in which two grouting materials are available and they can be easily exchanged
according to the change of ground condition. One is Solution-type grout which is suitable for dense
sandy ground, while the other is Suspension-type grout appropriate for clay or fissured ground. The
superiority of proposed grouting method has been confirmed as follows: First, through an injection test,
the solution-type grout has shown higher penetrability than urethane-based grout, and thereby
produced more cylindrical columns of solidified soil; Second, through an injection test using man-
made ground, the suspension-type grout was superior to cement-based grout; Finally, in order to
control surface ground settlement, this method has been successfully applied to work at tunnel portals.

REFERENCE

Date, K. Yamamoto, T. Kitamoto, Y. Haruyama, K. 2002, Evaluation of ground deformation induced

by tunneling with forepiling, ISRM International Symposium on Rock Engineering for Mountainous
Regions EUROCK2002, pp.335-342.

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