ML19319D720
| ML19319D720 | |
| Person / Time | |
|---|---|
| Site: | Crystal River, 05000303  (SUPP-2-2) |
| Issue date: | 08/10/1967 |
| From: | FLORIDA POWER CORP., GILBERT/COMMONWEALTH, INC. (FORMERLY GILBERT ASSOCIAT |
| To: | |
| Shared Package | |
| ML19319D718 | List: |
| References | |
| NUDOCS 8003240736 | |
| Download: ML19319D720 (30) | |
Text
' O, Excerpts From " Foundation Grouting Report Unit 2" O
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CONCEPT OF GROUTING CIDSURE After establishing the nature of the host rock for grout in'ection, it was decided that a split-spaced stage grouting technique could be relied upon to assure that the rock mass would be effectively grouted. Such grouting closure would be completed when:
1.
The acceptance of grout by the rock system had been decreased to a negligible quantity under an appropriately applied pressure for the depth of injection.
2.
Pemeability of the rock mass had been decreased to a value approximating the interstitial or primary pemeability of the rock.
The closure concept employed is a standard method which considers that after arriving at a primary hole spacing (accomplished by exploratory drilling, testing, and test grouting), an initial set of injection values (in this case cubic feet of grout injected per lineal foot of injection hole) should decrease to an insignificant or end value in subsequent order injections in split spaced holes (holes drilled midway between original holes).
According to Grant this injection value, termed unit take "... is a measure of bedrock conditions that can be translated into the effectiveness of the treatment, Under controlled operating procedures, this unit provides a common denominator for evaluating the grouting work at different parts of a foundation."
Grant, L. F. (1961+) Concept of Curtain Grouting Evaluation, Journal of Soil Mechanics Division of the ASCE, Vol. 90, SM1.
02l2 GIL B E RT AS SOCI A TE S, INC.
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8 It was then decided that a test grout curtain was necessary to establish optimum primary hole spacing and injection techniques before efficient production grouting could be performed.
TEST CURTAIN GROUTING Prior to the start of any drilling or grouting, an extensive testing program was performed. The purpose of the testing was to determine what
" quick set" or dehydrating additive would be the most useable and economical in production grouting to prohibit w:Ldespread intrusion of grout in unnecessary areas.
The four products tested were:
1.
SIKA NO. k 2.
DEHYDRATINE 80 3
POR-ROK h.
Calcium Chloride FOR-ROK was immediately eliminated because of a lack of dependability.
SIKA NO. k was prohibitive in cost with only a minor increase in dependability over the other products. DEHYDRATINE 80 gave good results at a moderate cost.
Calcium Chloride was proved best because of its low price and dependability.
After careful selection of the appropriate dehydrating agent, a test curtain was established between holes O and 20, located on the perimeter of the Boiler Room, as shown on Figures 1 and 3 The following list indicates the approaches, techniques, and materials employed in the test curtain:
1.
Neat cement grout only.
2.
Neat cement grout with calcium chloride.
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Sanded mixes only, b.
Sanded mixes with calcium chloride.
5 Intemittent injection.
6.
" slugging" (pressure pulsing).
7.
8.
2 mbination of Items 1 through 6.
An arbitrary distance of 64 feet was chosen for initial spacing of primary holes O and 20.
These two holes were both drilled to a depth of 20 feet. Neat cement grout was used initially. It was quickly discovered that as a first injection mix, neat cement grout was expensive and impractical because the highly pervious rock consumed such large quantities of the low viscosity mix.
An attempt was made to inject only a predetermined aaount of neat cement grout with enough calcium chloride to give a quick set. Neither neat grout nor neat grout with calcium chloride could be used to seal twenty-foot intervals by injecting only moderate volumes of grout.
Still not sealed, holes O and 20 were grouted with a 1:2 cement, sand mix. Moderate volumes of grout still could not render the injection intervals grouted. At this point, calcium chloride was added to the sanded mix, but it was not successful..The " slugging," or pressure pulsing technique likewise provided no measure of success, except in areas of loose material and small open seams.
Finally, a closely controlled intemittent injection program (attained by periodica11hinjecting predetermined quantities of grout in a single hole) was initiated. The initial injection laid a base upon which succeeding s
G I L B E R T A S S O C I A T E S. I N C.
10 injections were placed. This technique proved throughout the program to be the only method that veuld work successfully.
Next, the spacing of the holes and the effect on the host rock of the various grout mixes were determined. After completing holes 0 and 20 to a depth of 20 feet, hole No.10 was drilled to reduce primary hole spacing to 32 feet. coring hole 10 revealed no evidence of grout nor a significant change in the unit tate.
Next, secondary holes 4 and 14 were cored. There was an average decrease in unit takes of these two holes, as well as an occurrance of grout seams in hole 14.
Tertiary holes 2, 6, 12, and 16 were drilled. Grout seams were found in these holes. By the tertiary order, (8-foot spacing between injection holes) the unit take was down to acceptr'le limits for closure.
O Completion of grouting in the test curtain revealed the following:
1.
A split-spaced, stage grouting technique could be used.
2.
Primary holes should have a maximum spacing of 32 feet.
3 The tertiary order wculd be the lowest order in the standard pattern.
4.
Intermittent injection must be used to "close out" holes of higa grout consumption.
5 Sanded mixes are useful only in large voids.
Grouting operations performed subsequent to the test curtain showed that:
1.
Flyash mixes penetrated all but the smallest opening.
2.
Neat cement grout should be used as a waterpr afing agent upon the completion of normal grouting.
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11 3
A quaternary (4-foot) hole spacing should become a part of the standard injection ppttern. This need for closer hole spacing was not revealed in the test curtain because the grout was injected into rock that was better than averans for this site.
Initially all holes in the standard pattern were drL ded to a depth of 100 feet (except holes 0, 70, and 90). With time and experience it was found that varying depths could be assigned to the different order holes because with greater depth more pressure could be applied with the grout accordingly influencing a larger area.
The following list gives these depths:*
1.
Primary holes....
100 feet 2.
Secondary holes.
90 feet 3
Tertiary hole 80 feet k.
Quaternary holes 75 feet
- Note: These depths are based on a backfill elevation of 94 feet or lover.
Another phase of testing involved the use of AM-9 chemical Grout. The manufacturers of AM-9 furnished an engineer to supervise the program. The results of the testing revealed that such a chemical grout, if required, could effectively be used to create an impervious foundation, but only after a full standard grouting program. However, the expense was prohibitive especially in view of the fact that proper grouting techniques and neat cement grout could do the same job for 1/llth the cost, in 1/10th the time.
Consideration was given to the possibility of depressions in the dolomite below the area explored in the pre-grouting exploration program. To check for these possible depressions, three holes (Numbers 70, 90, and 0) in the curtain wall were deepened to 110 feet. In addition, several hoJes in the C. )'
consolidation grid were also deepened.
c i t. B E R T A S S O C I A T E S, I N C.
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O There was, as expected, an increase in the grout consumption in this lower area because it contained larger, cleaner fractures. It was shown, however, that the interval of 100 feet provided adequate penetratic n into dolomite without excessive loss of grout through vertical pemeation of the secondary rock structure (fractures).
PRODUCTION GROUTING, Grout Curtain In all cases the numbering system used to identf fy holes by their order, as shown on Figure 4. is as follows:
Hole numbers ending in: 0 - - - - - - - - - Primaries 4 - - - - - - - - - Secondaries 2 or 6 - - - - - - Tertiaries Odd Numbers - - - - Quaternaries A - - - - - - - - - Quinaries B - - - - - - - - - Senaries The following is a tabulation of the number of holes utilized in the three curtain walls surrounding the various areas of Unit No. 2.
Area Primaries Secondaries Tertiaries Quat. Quin. Sen. Total Boiler Room 18*
18*
36*
37 19 2
130 Turbine Room 12*
12*
2h*
22 4
74 Stack Area 8*
8*
16*
32*
8 72 Total 38 38 76 91 31 2
277 Indicates holes used in standard rattern Each hole in the standard pattern contained a minimum of three zones as shown on Figure 3 The depths of these zones were 20 feet (Zone I), 50 feet (Zone II), and the bottom of the hole (Zone III). However, a stage was created within a zone if problems were encountered, such as loss of drilling Oh 6 t L F E R T A S S O C I A T E S, I N C.
13 water or severe caving conditions within the hole. The quaternary, quinary, o
and senary orders, not considered a part of the standard pattern (except in the Stack Area where quaternaried were standard), were located at points where pressure and/or grout take indicated that the hole did not close out properly. The depths of these holes were determined by the location of areas of unusual grout take.
The depths of the three zones were determined by the following rationale:
Zone 1 (20 feet) -- This interval involved from 10' to 16' of casing inserted through the backfill and into 1+'
to 10' of caprock. With the bottom of the hole in comparatively good rock, grouting efforts could be concentrated on effectively sealing the surface rock and backfill material. Any greater hole depth would penetrate the caprock altogether.
Zone II (50 feet) -- This depth was in reality an arbitrary figure which fell in an area that presented a segment of hole that was not too lengthy, pierced the caprock completely, and penetrated the problem area of the foundation. This zone of grouting usually was bottomed in the differentially cemented limerock.
Zone III -- Although dolomite was generally encountered at 70 feet, the depth of 100 feet for primary and secondary orders was necessary to penetrate the steeply dipping fractures in the dolomite for proper containment of the silts and sands in the overlying transi-tion -zone, which generally was encountered in the upper portions of this zone. Also, the curtain wall had to be deep enough to insure complete containment of all grout injected during consolidation grouting.
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lh The following data obtained during the curtain grouting process shows in 9
sumary fom that successive order grout injections provided effective grout-ing closure.
Sumary of Curtain Grouting
- Hole order Feet Drilled Cubic Feet Grout Injected Unit Take (cuft/in)
Primary 3826 105393 27.50 Secondary 3801 29596 7.80 Tertiary 7242 23975 3 30 quaternary 7150 5534 o.77 quinary 1610 821 o.51 Senary 100 20 0.20 Total 23729 Total 165339 Ave.
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- See Appendix D for complete Grouting Records Grouting operations were conducted by drilling and grouting a single curtain zone (regardless of the number of stages) of at least two consecutive O
primaries. From this point, the same zone was grouted in the secondary hole located exactly between the two primaries. Finally, the tertiary holes were drilled and grouted on both sides of the secondary.
If, at this point, a tertiary hole took too much grout, it was closed in upon by two quaternary holes located on either side of the tertiary and in the plane of the curtain wall. Splitting of each succeeding order continued until closure was made, e.
g.,
a negligible grout take was arrived at under the appropriately applied pressure. The grouting of the curtain valls around the three areas, (Boiler Room, Turbine Room, and Stack Area) was straightforward and involved only minor changes in the procedure developed in the test curtain.
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G I L a E R T A s s 0 C I A T E S, I N C.
15 Only three anomolies existed in the entire grouting of the curtain wall.
These were:
1.
The high unit takes of the primary order.
2.
The extreme tightness of the silt and sand in the closing orders caused by densification of the material through grouting.
3 The unexpected large quantities of silt and sand encountered in the foundation.
It might be mentioned that the problems caused by these highly densified materials were even further amplified in consolidation grouting.
Although it was detemined that no continuum of interconnections existed in the rock structure, there were features which caused grout to " prefer" certain routes of travel while being pumped. Definite travel was traced for as far as 90 feet along these " preferred" routes which appeared to be oriented along a northwest - southeast trend.
One such feature passed through the Turbine Room. Referring to Figure 1, the northeast edge of this " preferred" route entered the north edge of the Turbine Room at hole 260 and exited at the east edge of the Turbine Room at hole 316. The southwest edge of this same feature entered the west edge of the Turbine Room at hole 220, headed toward curtain hole 70 and bent around to exit at the east wall of the Boiler Room at hole 100.
Another prominent route existed in the Boiler Room. The northeast edge started at curtain hole 212, headed east to hole 50 and then bent to exit at hole 110 on the east side of the Boiler Room. The southwest border started at hole 27 and headed in nearly a straight line to hole 1214 J
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0220 G I L B E R T A S $ 0 C I A T E S. I N C.
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16 The problem areas just described, contained large quantities of silt and sand from elevation 65 down to dolomite at about elevation 25 Three dimen-sional grout travel occurred within these areas. Grout was injected at a depth of 70 feet and was found to communicate to holes only 20 feet deep.
Consolidation The following summarizes the distribution of grout injection holes utilized in the consolidation grouting process:
Area Primaries Secondaries Tertiaries Quaternaries ToteJ*
Boiler Room 63 72 135 9
279 Turbine Room 50 45 95 190 Stack Area 21 16 32 69 Total 134 133 262 9
538 For order of holes, refer to Appendix B; for location, refer to Figure 1.
Each consolidation hole contained a minimum of two zones which were fonned at depths of 20 feet (Zone I), and at the bottom of the hole (Zone II). However, as in curtain grouting, a stage was created whenever anomolous conditions were encountered.
In Zone I, primary holes were drilled and grouted first, creating a 16-foot, square grid pattern. Next, the holes in the center of each square Brid were drilled and grouted. These holes were the secondaries. Finally, unless further " splitting" was necessary, tertiary holes were drilled and grouted to the bottom of Zone I.
This operation filled in all spaces left after the primaries and secondaries were drilled and grouted.
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O G I L B E R T A S S O C I A T E S, I N C.
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17 When holes were to be taken to their final depths, every second primary c
was drilled and grouted, creating a square grid of 32 feet. Then, the remain-ing primaries were completed and the final orders were completed as for Zone I.
Initial unit take figures were considerably less for consolidation grout-ing than for curtain grouting. An eight-foot grid pattern and a tertiary order closing hole produced a well consolidated foundation with closing order unit takes consistent with those of the grout curtain. A summary of these values is tabulated below.
Summary of Consolidation Grouting
- Hole order Feet Drilled Cubic Feet Grout Injected Unit Take (cuft/ft)
Primary 12077 39990 3 30 Secondary 20594 9390 0.89 Tertiary 18342 10278 o.56 Quaternary 180 50 0.28 Totals 41193 59708 1.45 See Appendix E for complete Grouting Records The problems encountered in the consolidation were merely amplifications of those encountered in the curtain, and new methods were devised to cope with them. These problems were related to the extensive occurrences of sand and silt, prevalent in the interval from 30 feet to 70 feet deep. In the early phases of the work, it was hoped that the sandy condition was localized and small enough so that sands and silts could be pumped from the hole, leaving a void that could be replaced with grout. Attempts to remove these materials from the rock mass were successful but too costly and time con _ aning.
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G I L B E R T 4 5 5 4 C l 4 T E S, I N C.
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1R Large volumes of such material were found to exist and to be mobile during grouting.
It therefore became necessary to densify these loose materials in situ.
Injection of grout started a process of densification as it displaced the silts and sands. Subsequent drilling into this zone became increasingly more difficult as the densification process neared completion. This dif-ficulty was caused by an increase in the incidence of caving conditions in closing order injection holes. With the hole caved, grouting of this interval was impossible by using the conventional method of grouting from the collar of the hole.
In order to densify these zones a circuit grouting procedure was developed. Initially, 3/4 inch galvanized pipe was washed down through the sand (EX, AX, or BX flush-joint packer pipe was not available) to the bottom of the hole. A packing gland was placed around the pipe and inserted at the O
collar of the hole to make a sealed system. The packing gland had a return spigot which returned the excess grout not accepted by the hole to the grout tub.
Such a technique proved to be impractical for the following reasons:
1.
These lengths of 3/4 inch pipe could rarely be washed to the bottom of the hole.
2.
Once the pipe was seated, not enough volume of grout could be pumped through the pipe to flush the sand and create circula-tion through the return spigot.
3 When it was time to remove the pipe, the coupled joints slowed down the operation so much that the hole either sealed off or the pipe became " grouted in," or both.
O Oz,.o htLHERT A S S O C l 4 T E S, I N C.
19 From this initial approach it was learned that:
1.
A means must be devised to permit the use of the drilling rig in inserting and removing the pipe.
2.
Flush-joint pipe had to be procured.
3
. A larger diameter of pipe had to be used to allow greater grout
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flow.
h.
A means of keeping the pipe moving at all times to prevent seal-
,ing off had to be deviced.
It was therefore decided that the drill rods could be used as injection pipe. The only problem was, that in order to keep the rods moving at all times, it would be difficult to use a packing gland at the collar of the hole.
Therefore, this newly assembled equipment was tried without a packing gland.
The rods were inserted to the bottom of the hole while the drill was kept rotating, and as grout was injected, the rods were also raised and lowered.
, O If a return occurred at the collar of the hole, the grout flow was regulated to equal'the consumption rate of the hole. As the rods were raised and lowered, the hole showed a tendency to stay open. At this point, a 10-foot i
l section of drill rod was rapidly removed, and the same procedure continued until all of the caved area was secured. When circuit grouting was completed, the rods were quickly removed and a header was attached to the nipple for 3
groutin6 to refusal in the conventional manner. When the grout had set, it was redrilled and deepened for regrouting.
l Although an effective grouting techaique was develcped, the densified g.-
sand presented a definite drilling problem. When drilling secondary or I
tertiary order holes, the dri~il rods were seiced by the densified sand.
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-Drill operators had to increase circulating fluid flow rates and RPM's of 0224 4
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20 the drill string, while decreasing the drilling pressure and watching the drill water return. Without such careful drilling practices the drill string and hole were generally lost.
In the area of core hole BRE-8, drilling revealed a depression in the dolomite. To insure that any possible settlement was arrested, holes in this entire area were extended to as deep as 110 feet.
EVALUATION OF GROUTING EFFECTIVHIESS The effectiveness of the grouting program has been evaluated on the basis of the following criteria:
1.
Pemeability comparisons of before grouting and after grouting.
2.
Drill water loss compared to hole order.
3 Unit take analysis.
4.
Core recovery comparisons of before grouting and after grcuting.
5.
Seismic velocity studies.
6.
observation of an open excavation.
Pemeability Tests As previously mentioned, all approaches to pre-grouting pemeability testing indicated only that the foundation had a pemeability in excess of 65,500 feet / year (6.5 x 10-2 cm/sec).
Pemeability tests conducted in the post-grouting exploratory holes yielded values which ranged from 2 9 x 10-3 cm/see to zero. These values represent a 96 to 100% reduction in the original pemeability of the rock The results of these tests are tabulated in Appendix C of this report.
mass.
Pemeability values obtained in the laboratory by testing core samples, f
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a 21 both horizontal and perpendicular to the primary depositional features were b
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Hori (x10-gontal cm/sec)
(x 10-3 cm/sec)
Hole No.
Dg']
BRE-14 50' 6.79 0.74 BRE-18 44' 7.04 1.12 TRE-1 55' 1.15 1.03 TRE-5 53' 2.03 34.0 TRE-8 34' l.30 6.30 TRE-11 31' 1.29 1.04 It is seen that these values are slightly higher than post grouting values, indicating that the vast secondary pemeability due to fracturing and/or solution activity has been effectively eliminated and suggesting that the grouting process has decreased even the primary or interstitial pemea-bility of the foundation rock system.
Drill Water Losses U
When drilling and grouting first began, circulation of drill water was lost within the first 14 feet (10 feet of which was casing) of hole. When the area of loss was grouted, circulation was restored until drilling penetrated the grouted zone, at which point circulation was again lost almost immediately.
Logically, as the spacing between injection holes decreased it was anticipated that the frequency of drill water loss should similarly decrease.
This hypothesis is substantiated as shown by Figure 4 and the following tabulation of water losses for curtain holes and consolidation holes. Also, the percent of water losses compared to the number of stages drilled in each order is shown, since this is more meaningful due to the increase in the number of holes as hole order increases.
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22 NUMBER AND PERCENT OF WATER IDSSES PER ORDER OF HDLE CURTAIN order of Hole Times Water Lost No. of Stages Percent Loss Primary 71 166 42.8%
Secondary 14 125 11.2%
Tertiary 11 2h1 4.6%
Quarternary 3
200 1.5%
Quinary o
35 0
Senary 0
2 0
CONSOLIDATION Order of Hole Times Water Lost No. of Stages Percent Loss Pri=a.
31 292 10.6%
Secc,ndary 3
314 1.0%
Tertiary 3
531 o.6%
Quaternary 0
8 0
Quinary 8enary Note: See Figure 4 Unit Take Analysis The concept of grouting closure as set forth on page 7 states that with effective grouting the unit take of successively split spaced injection holes should decrease. The results of such a comparison are shown on Figure 5 as tabulated below.
UNIT TAKE PER ORDER OF HOLE Order of Hole Curtain Unit Take Consolidation Unit Take Primary 27.50 3.1' Secondary 7.80 0.89 Tertiary 3 30 o.56 Quaternary o.77 o.28 Quinary 0 51 Senary 0.20 Average 7 00 1.h5 G I L B E R T A S S O C I A T E S, I N C.
23 Core Recovery Ccmparison
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Pre-grouting exploratory core drilling core recovery figure values were lower than post-grouting core recovery values. These higher post-grouting values are attributed to:
1.) The densification process made the uncemented sands and silts more resistant to the erosive action of the drilling process, and consequently easier to recover.
2.) Grout seaa.
are recovered in areas where loose sand had been densified (volumetrically decreased), thus making space available for grout. 3.) Grout seams were found where open solution channels or voids existed prior to grouting. The increase in post-grouting core recovery was as high as 85fo over the pre-grouting core recovery.
Seismic Field Testing Post grouting values of seismic shear wave velocities, (from which defe mation modulus of the rock system was computed) were not observed to increase significantly as a result of the grouting process. However, the fact that these values did not increase, coupled with the fact that down hole velocity measurements did not reveal any seismic stratification, offer the suggestion that the overall percentage of loose materials in the founda-tion rock system (those subject to densification) is neither large enough nor continuous enough to be recorded and therefore densifying them would have no effect on the overall seismic velocity of the rock mass.
Observation of Pit Excavations One of the most revealing proofs of effective grouting is the observation of an actual pit excavated in the grouted area.
The flume excavation in the Boiler Room was made to elevation 82, six feet below the level of mean low tide. At full excavation depth, a single pump was adequate to maintain the excavation dry enough to work in.
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24 grouted solution channels, cavities and joints in the rock were observed in the excavation as shown on Figure 6.
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APPENDIX C r" '
POST-GRoUTIIU PERMEABILITY TESTS k
% Reduction in Hole No.
Interval Feet / year Cm/see Permeability BRE-22P o-loo 2000 2
x 10-3 97%
BRE-24P o-26 2640*
2.6 x 10-3 96%
3 26-36 1420 1.4 x 10 4 98%
36-46 950 95x10k 99%
46-56 271 2 7 x lo-99%+
56-66 o
o 100%
66-76 o
o 100%
76-91 1940 1 9 x 10-3 97%
BRE-26P o-25 1930 19 x 10-3 97%
25-45 3000 3 0 x 10-3 95%
45-90 240 2.4 x 10-4 99%
BRE-27P o-26 745 7 4 x 10-4 99%+
26-36 o
o 100%
36-56 1350 13 x 10-3 98%
56-66 o
o 100%
66-101 2930**
2 9 x 10-3 96%
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o-80 1750 1 7 x 10-3 97%
O 2
o-50 76u 7.6 x 10 '
99*+
lo o-50 956 9 5 x 10-4 99%
11 0-20 o
o 100%
26 o-20 1910 1 9 x 10-3 97%
32 o-50 1530 1 5 x 10-3 98%
50 o-80 1700 1 7 x 10-3 97%
52 0-100 1366 1 3 x 10-3 98%
60 0-50 384 3 8 x lo-99%+
64 o-loo 1760 1 7 x 10-3 97%
66 o-50 liso 1.1 x 10-3 98%
74 0-80 109 1.0 x 10-4 99%+
80 0-100 2260 2.2 x 10-3 975 Note: Water leakage to backfill n g,. n Note: Hole penetrated the limits of grouting UCJ7
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D Holes o through 166 vere tested before groutirig in the area had
- Note:
been completed C-1 w..
APPENDIX C POST-GROUTIh PERMEABILITY TES'IS
% Reduction in Hole No.
Interval Feet / year Cm/see Pemeability 92 0-80 135o 1 3 x 10-3 98%
106 0-100 1300 1 3 x 10-3 98%
126 o-loo 2010 2.0 x 10-3 97%
132 o-so 166o 1.6 x 10-3 98%
146 0-100 2170 2.1 x 10-3 97%
150 o-loo 1270 1.2 x 10-3 98%
162 0-100 2770 2 7 x 10-3 96%
166 o-90 2380 2 3 x 10-3 96%
O 02 0 0
C-2