Grouting and tunnel support system for NJHPP

GROUTING AND TUNNEL SUPPORT SYSTEM FOR THE SAFE EXCAVATION
OF TUNNEL IN NEELUM JHELUM HYDRO POWER PROJECT
By
Ameer Hamza Sundal

Awais Iqbal
Umair Javaid
Supervisor Mr. Saqib Mehmood
Department of Earth and Environmental Sciences
Bahria University Islamabad

2018
EVOLUTION OF THE PRECAMBRIAN CRUST EXPOSED IN SARGODHA AREA, PUNJAB, PAKISTAN
BS Thesis Defence
CONTENTS
 Introduction
 Stratigraphy
 Tectonics
 Objectives
 Methodology
 Conclusions
GROUTING AND TUNEEL SUPPORT SYSTEM FOR THE SAFE EXCAVATION OF TUNNEL IN NJHPP Slide2
INTRODUCTION
(Norconsult, 1996)
GROUTING AND TUNEEL SUPPORT SYSTEM FOR THE SAFE EXCAVATION OF TUNNEL IN NJHPP Slide 3
TECTONICS
(Masrour, 2017)
TECTONICS
(Masrour, 2017)
STRATIGRAPHY
Foramtion Age
Quaternary alluvium Recent

Unconformity
Mirpur Formation Pleistocene
Unconformity
Soan Formation Pliocene
Dhok Pathan Formation Late Miocene
Nagri Formation Late Miocene
Chinji Formation Middle to Late Miocene
Kamlial Formation Early to middle Miocene
Murree Formation Early Miocene
Kuldana Formation Middle to Late Eocene
Chorgali Formation Early Eocene
Margalla Hill Limestone Early Eocene
Patala Formation Late Paleocene
Lockhart Limestone Early Paleocene
Hangu Formation Early Paleocene
Unconformity
Muzaffarabad Formation Cambrian
Unconformity
Dogra Formation Precambrian
Unconformity
Precambrian Basement rocks (IJSRP, Vol. 7, Issue. 7, 2017)
STRATIGRAPHY OF STUDY AREA
Formation Age Lithology
Silt, gravel and unconsolidated

Alluvium Recent
deposits of clay
Mostly clays, shales and

sandstone and mudstone.
Sandstone is red to purple red
Murree Formation Miocene
in colour and is fine to medium
grained while shales are
reddish maroon
OBJECTIVES
Assess Q value of the rock units exposed in the study area
To evaluate the excavation method for tunnelling
To design support used during excavation process
METHODOLOGY
Tunnel Support
Analysis
Q-Value Excavation Technique Support
Q-Value
Q-Value
Inter-block
Block Size Active Stress
Shear Strength
Rock Quality Joint set Joint roughness Joint Alteration Joint water Stress Reduction
Designation numbers Number Number reduction factor Factor
Q-Value Formula
Q =( RQD / Jn) × (Jr / Ja) ×( Jw / SRF)
(Barton et al 1974)
Q-Value
Q1 Q2 Q3 Q4 Q5
Exceptionally Extremely Exceptionally

Very Good Good Fair Poor Very Poor Extremely Poor
Good Good Poor
a b c -- -- a b a b
400<Q<1000 100<Q<400 40<Q<100 10<Q<40 4<Q<10 1<Q<4 0.1<Q<1 0.01<Q<0.1 0.001<Q<0.01
Subdivisions of Q-Values
(Barton et al 1974)
Calculations
Lithology RQD Jn Jr Ja Jw SRF Q value Rock Quality
Mudstone 95 6 1.5 3 1 1 7.9166667 Q3
Sandstone 30 12 1.5 6 1 2.5 0.25 Q4b
Mudstone 10 20 1 8 1 5 0.0125 Q5a
Sandstone 25 6 1.5 4 1 5 0.3125 Q4b
Mudstone 60 6 1.5 4 1 2.5 1.5 Q4a
Road Header
Figure. Road Header
TUNNEL BORING MACHINE
Figure.TBM used for tunnel excavation in NJHPP
Initial Support
Supports
Reinforced Grout (if Lattice Umbrella

Shotcrete Ribs of Rock Bolts
needed) Girder Arches
Shotcrete
Single Double Project Pipe

Swellex Self Drilling Spiling
Layer Layer Specific Canopy
Sprayed Concrete (Shotcrete)
Figure. Shotcrete sprayed (arrow) by workers (oval) at C2 Majohi Figure. Shotcrete spray (random)
Grouted Rock bolts
Figure. Grouted Rock Bolt (blue oval) A4, Majohi Figure. Swellex Rock Bolt
Grouted Rock Bolts
Figure. Water flowing from bore hole (red circle) A4, Majohi Figure. Rock Bolt installation C2 Majohi
Reinforced Ribs of Shotcrete (RRS)
Figure. Single Layer RRS (with swellex), C2 Majohi Figure. Project specific RRS, C2 Majohi
Lattice Girders
Figure. Lattice Girders at portal of Addits(A2,A3,A4&A4a) & Tunnel (T3L)
Figure. Shotcrete sprayed on Lattice Girder
Umbrella Arches
Figure. Spiling
Figure. Pipe Canopy installation with new system
Challenges
Serial
Tunnel Section Type of Failure
No.
1 TL Roof collapse-Chimney type failure
2 TR Chimney type failure of roof & Exceptionally high water inflow
3 TL Major water flow from invert
4 TR Shotcrete failure & Major water inflow
Roof Collapse
Figure. Deposit of muck material on top of collapse debris C2, Majohi
Figure. Shotcrete wall
Roof Collapse Rehabilitation
Figure. Concrete backfilling of roof
Figure. Chemical (PU) grouting

Collapse & Water Ingress Rehabilitation
Figure. Buttressing Tunnel Face with muck and sand bags Figure. Water Flowing through drain holes (red circles)
Collapse & Water Ingress Rehabilitation
Figure. Tunnel Plug (temporary)
Major Water Inflow (invert)
Figure. Flooded Invert Figure. Water diversion through channelling
Major Water Inflow (invert) Rehabilitation
Figure. Concrete Slab Installation
Shotcrete failure & Major water ingress
Figure. Shotcrete blowout & water ingress (white arrows) Figure. Damaged side wall
Shotcrete failure & Major water ingress
Figure. Shotcrete wire mesh
Figure. Drain holes
Conclusions
The rock quality was highly heterogeneous so the Q value assessed are between Q1 to Q5.
Slow progress of Drill and Blast technique led to a change in excavation method so TBM was selected
as the best choice for excavation due to its fast pacing and automated functionality.
Due to high water content some support systems were customized like Reinforced Shotcrete Rib,
Lattice Girders, Rock bolts & Pipe canopy System for project specific installation. To overcome
challenges in the tunnel tunnel plug, concrete plug, buttressing and remediation grouting was used.
Q-Value parameters
RO CK Q UAL IT Y DE S IGNAT IO N JO INT S E T NUMB E R VAL UE J O I NT WAT E R RE DUCT I O N

FACTOR
RQD Jn
Jw
120 25
100 20 1.2
15 1
0.8
Jn
80
Jw
10 0.6
RQD
60 5 0.4
0.2
40 0 0
20
0
VERY POOR POOR FAIR GOOD EXCELLENT
Class No. Of Joint Sets Inflow
JO I NT RO UGH NE S S NUMB E R JO INT ALT E RAT IO N NUMB E R S T RE S S RE DUCT I O N FACTO R

Jr Ja SRF
5 15 15
4
3 10 10
SRF
Jr
Ja
2 5
1 5
0 0
0
Roughness Alteration Stress Zones

Grouting and tunnel support system for NJHPP

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GROUTING AND TUNNEL SUPPORT SYSTEM FOR THE SAFE EXCAVATION

OF TUNNEL IN NEELUM JHELUM HYDRO POWER PROJECT

Ameer Hamza Sundal

Supervisor Mr. Saqib Mehmood

Department of Earth and Environmental Sciences

Bahria University Islamabad

Quaternary alluvium Recent

Formation Age Lithology

Silt, gravel and unconsolidated

Mostly clays, shales and

Assess Q value of the rock units exposed in the study area

To evaluate the excavation method for tunnelling

To design support used during excavation process

Q-Value Excavation Technique Support

Q =( RQD / Jn) × (Jr / Ja) ×( Jw / SRF)

Exceptionally Extremely Exceptionally

400<Q<1000 100<Q<400 40<Q<100 10<Q<40 4<Q<10 1<Q<4 0.1<Q<1 0.01<Q<0.1 0.001<Q<0.01

Lithology RQD Jn Jr Ja Jw SRF Q value Rock Quality

Mudstone 95 6 1.5 3 1 1 7.9166667 Q3

Sandstone 30 12 1.5 6 1 2.5 0.25 Q4b

Mudstone 10 20 1 8 1 5 0.0125 Q5a

Sandstone 25 6 1.5 4 1 5 0.3125 Q4b

Mudstone 60 6 1.5 4 1 2.5 1.5 Q4a

Figure. Road Header

Figure.TBM used for tunnel excavation in NJHPP

Reinforced Grout (if Lattice Umbrella

Single Double Project Pipe

Figure. Lattice Girders at portal of Addits(A2,A3,A4&A4a) & Tunnel (T3L)

Figure. Shotcrete sprayed on Lattice Girder

Figure. Pipe Canopy installation with new system

1 TL Roof collapse-Chimney type failure

2 TR Chimney type failure of roof & Exceptionally high water inflow

3 TL Major water flow from invert

4 TR Shotcrete failure & Major water inflow

Figure. Deposit of muck material on top of collapse debris C2, Majohi

Figure. Shotcrete wall

Figure. Concrete backfilling of roof

Figure. Chemical (PU) grouting

Figure. Tunnel Plug (temporary)

Figure. Flooded Invert Figure. Water diversion through channelling

Figure. Concrete Slab Installation

Figure. Shotcrete wire mesh

Figure. Drain holes

RO CK Q UAL IT Y DE S IGNAT IO N JO INT S E T NUMB E R VAL UE J O I NT WAT E R RE DUCT I O N

JO I NT RO UGH NE S S NUMB E R JO INT ALT E RAT IO N NUMB E R S T RE S S RE DUCT I O N FACTO R

Roughness Alteration Stress Zones

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