TUAS WATER RECLAMATION PLANT
CONTRACT 2A – INFLUENT PUMPING STATIONS
Method Statement for Fissure Grouting
Koh Brothers – China Harbour Joint Venture
TUAS WATER RECLAMATION
PLANT – CONTRACT 2A
Method Statement for Fissure Grouting
TUAS WATER RECLAMATION PLANT
CONTRACT 2A – INFLUENT PUMPING STATIONS
Method Statement for Fissure Grouting
Contents
INTRODUCTION........................................................................................................................................ 1
SCOPE OF WORKS .................................................................................................................................. 2
LOCATION AND LAYOUT OF WORKS ................................................................................................... 2
FISSURE GROUTING METHODOLOGHY ............................................................................................... 2
DRILL HOLE LAYOUT .................................................................................................................... 3
DRILLING METHOD IN ROCK........................................................................................................ 4
DRILLING AND GROUTING SEQUENCE ............................................................................................... 4
OVERALL GROUTING SEQUENCE .............................................................................................. 4
ROCK FISSURE GROUTING SEQUENCE .................................................................................... 4
LIMITING CRITERIA FOR GROUTING VOLUME AND PRESSURE ............................................ 6
GROUT TESTING...................................................................................................................................... 7
PUMPING TESTS ...................................................................................................................................... 7
TUAS WATER RECLAMATION PLANT
CONTRACT 2A – INFLUENT PUMPING STATIONS
Method Statement for Fissure Grouting
INTRODUCTION
Site Development Works under Contract 2A for Tuas Water Reclamation Plant (TWRP) will be
deployed as part of the Deep Tunnel Sewerage System Phase 2 project. A conveyance system of
link sewer and deep tunnel sewer to transport used water by gravity to centralized WRPs in coastal
areas is employed by DTSS. The used water is treated and further purified into high-grade reclaimed
water (NEWater) with any excess treated used water that is not used for process or other plant water
needs, being discharged to the sea.
In order to facilitate used water treatment and the production of NEWater, there will be two tunnels
to convey Industrial Used Water (IUW) and Domestic Used Water (DUW) to TWRP separately.
Overall, TWRP will employ advanced treatment process to minimize specific energy consumption
and sludge production and at the same time maximize water recovery for re-use and biogas
production for the generation of electricity.
TWRP will be located at Tuas View Basin (TVB) in the western end of Singapore. TVB is a piece of
reclaimed land, bounded by the existing Tuas Power Generation facility (TPG) and its seawater
intake channel to the north and west respectively, and the sea to the east and south.
The major facilities to be constructed under this contract include:
i) Influent Pumping Stations
a. Industrial Used Water Coarse Screen Shaft
b. Industrial Used Water Influent Pumping Station
c. Domestic Used Water Coarse Screen Shaft
d. Two numbers of Domestic Used Water Influent Pumping Station
e. Odour Control Facility
ii) Two numbers of 66/22kV Electrical Main Substations
TWRP
Figure 1 - TWRP Site Layout
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TUAS WATER RECLAMATION PLANT
CONTRACT 2A – INFLUENT PUMPING STATIONS
Method Statement for Fissure Grouting
SCOPE OF WORKS
Contract 2A includes the provision of site-wide temporary and permanent infrastructures as well as
services for the duration of the contract period. This includes the following:
1. Permanent Works;
2. Site Enabling Works;
3. Support services during construction of TWRP;
4. BIM Delivery; and
5. Other activities.
LOCATION AND LAYOUT OF WORKS
The below figure showing the location of Coarse Screen Shaft (CSS), Influent Pumping Station (IPS),
Odour Control Facility (OCF), Main Electrical Sub Stations and the Staging area.
Coarse screen shaft, Influent
Pumping Station and Odour
control facility
Staging
Area
Main Sub Stations
Figure 2 - Overall Site Layout Plan
FISSURE GROUTING METHODOLOGHY
The purpose of fissure grouting is to reduce the permeability of the rock surrounding the shaft. Prior
to carrying out fissure grouting, grouting trials shall be carried out to verify the grouting pressure,
sequence, procedures and grouts. The use of an observational approach is essential to achieve
effective grouting. The below figure showing the propose fissure grouting in the rock for vertical shaft.
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TUAS WATER RECLAMATION PLANT
CONTRACT 2A – INFLUENT PUMPING STATIONS
Method Statement for Fissure Grouting
Diaphragm Wall
Fissure Grouting Layer
(min 3m width)
Figure 3 – Indication of Fissure Grouting for Vertical Shaft
DRILL HOLE LAYOUT
Figure 4 – Typical Drill Hole Layout
The grout points in wall (A & B points) can be positioned in front or back face of the wall, and do not
have to be consistent provided the 1200 to 1500mm spacing along the wall is maintained. If any of
the ducts for A & B holes are missing or blocked, they can be replaced by drilling additional hole(s)
on the outside or inside of the wall. If there are additional ducts in the wall, these can be used for
drilling or D holes.
There will be two types of hole:
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TUAS WATER RECLAMATION PLANT
CONTRACT 2A – INFLUENT PUMPING STATIONS
Method Statement for Fissure Grouting
• Hole drilled through ducts placed in the wall; these holes are used for toe grouting and
rock fissure grouting. The number and location of these ducts depend on what the ERSS
wall contractor has managed to install.
• Holes drilled outside (or, if necessary, inside) the wall; these holes are used for rock
fissure grouting only.
DRILLING METHOD IN ROCK
In the rock, percussion drilling will be required, using a down-the-hole hammer (DTH) to advance
the grout hole.
DRILLING AND GROUTING SEQUENCE
OVERALL GROUTING SEQUENCE
As fissure grouting is proposed around the perimeter of in rock formation (wall and base), alternate
C holes are drilled and grouted first, followed by D holes. The sequence and the water testing and
grouting criteria given here are for planning purpose only. After each round of grouting the results
will be reviewed. Where necessary, modification can be made.
ROCK FISSURE GROUTING SEQUENCE
The general sequence will consist of:
• Drill with casing into the top of rockhead.
• Drill to the planned base of the hole
• Grout in upward stages, using a single packer in the rock.
• Check holes to test the effectiveness of the grouting will be drilled after the completion of
all of the grouting at an intervention block.
VERTICAL SEQUENCE
The vertical sequence will depend on the length of the hole in rock. The general sequence will be :
• Top stage: Rockhead to 1.5m below rockhead.
• Middle stage: 1.5m below rockhead to 5.5m below rockhead.
• Basal stages: stages between the base of the hole and the base of the intermediate stage,
maximum stage length of 5m.
Generally, bottom-up grouting will be used, i.e. basal stages, followed by intermediate stage and top
stage. However, this can be reversed (top-down) grouting if there is evidence of hole instability in
the rock.
DRILLING
The drilling of each hole consists of:
• Wash bore casing down to rockhead and seat into rock.
• Percussion drill to required base of hole.
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TUAS WATER RECLAMATION PLANT
CONTRACT 2A – INFLUENT PUMPING STATIONS
Method Statement for Fissure Grouting
• Flush out hole to clear any remaining cuttings.
WATER TESTING
Before carrying out any water testing, layout the planned length of grout hose and packer on the
ground. Carry out pressure loss test, by injecting water at a rate of 10 l/min and recording the
pressure at the gauge. This test is done before the start of any water testing and is only repeated if
the length of grout hose changes significantly, or the packer changes. Record the pressure required
to maintain the flow rate of 10 l/min. For each stage of water testing:
• Locate packer at the specified depth for the stage and inflate to seal.
• Inject water until the pressure reaches 5 bars, and the flow rate has stabilized. Record the
time and volume of water injected to this initial injection.
• Inject water, holding the pressure constant at 5 bars for 5 minutes. Record volume of water
injected every 0.5 minute.
FISSURE GROUT MIXES
Generally, all rock fissure grouting will be using MFC grout, unless a higher permeability (>50 lugeon
units) zone, such as a fault zone, is encountered. Two typical OPC grout mixes are given below.
The grout mixes comprise:
OPC Mix 1 W:C 1:1 + 1% to 3% (by weight of cement) bentonite
OPC Mix 2 W:C 0.5:1
MFC Mix 1: W:MFC 1:1
MFC Mix 2 (Viscous Mix) : W:MFC 0.9:1
Grout mixes can be varied from those given above, provided that the limiting properties given in
Table 1 to 4 are met.
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TUAS WATER RECLAMATION PLANT
CONTRACT 2A – INFLUENT PUMPING STATIONS
Method Statement for Fissure Grouting
LIMITING CRITERIA FOR GROUTING VOLUME AND PRESSURE
Limiting (i.e. stop grouting) criteria are given as a limiting volume and a limiting pressure and a
specified grouting “hold” time, with general criteria to avoid loss of grout and damage to buildings
and utilities.
PRESSURE CRITERIA
The pressure criteria are given in table below.
In order to adjust to varied rock conditions and build the grouting pressure, the grouting on any stage
continues until the limiting pressure and hold time are reached. If the grout is observed to flow to the
ground surface (except where it is up another hole), stop grouting on the hole, to allow some
hardening of the grout, and then recommence grouting. If the grout still surfaces, flush the hole of
grout and leave for at least 12 hours. After 12 hours the grouting may recommence on that hole.
Drilling and grouting on other holes may continue, provided that there is no evidence of grout injected
into those other holes coming to surface. If the grout is observed coming up other duct(s) from the
one being grouted, the other duct(s) can be sealed temporarily by placing an expanded packer at
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TUAS WATER RECLAMATION PLANT
CONTRACT 2A – INFLUENT PUMPING STATIONS
Method Statement for Fissure Grouting
the top of the duct, and closing off the grouting pipe in the center of the packer. Alternatively, grout
the communicating holes simultaneously, or alternate grouting back and forth between the
communicating holes. If the measured heave on the ground surface due to grouting work exceeds
15mm, or 10mm stop grouting and review.
GROUT TESTING
Grout testing will be divided into routine testing and full suite testing. The routine testing comprises
regular checks made at least daily during active grouting; the full suite testing is an enhanced suite
of tests carried out if the materials or supplier are changed, there is a new delivery, or other reason.
Routine testing will be carried out at least once per half day that there is active mixing and injection
of grout. Testing will be carried out on the grout(s) being actively mixed and injected in that half day.
Each day is divided into morning and afternoon periods. If no grout mixing or injection is carried out
in a period, no testing is carried out. If grouting is carried out in either period then a set of routine
tests for the grout is carried out during the period.
Full suite testing will be carried out when: (i) there is new delivery of grout; (ii) there is new delivery
of superplasticizer (if being used); (iii) a mix fails to meet any of the limiting values for routine testing;
(iv) the mix is changed from that set out; (v) a different mixer from that used for the trial is used.
PUMPING TESTS
Pumping tests will be carried out after the completion of grouting.