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CIVIL WORKS
1.8 Drilling & Grouting
1.8.1 Introduction
This Section covers the Boards requirements for the drilling and grouting to be provided
for various structures at site.
Consolidation grouting, contact grouting and or crown void grouting shall be provided
wherever required in the tunnel.
1.8.2 Reference Standards and codes
IS:6066-1984 - Recommendations for pressure grouting of rock foundations in
river valley Projects
IS:5878 (Part VII)-1972 -Code of practice for construction of tunnels conveying
water (Grouting)
IS:5878 (Part II/Sec 1)-1970 - Code of practice for construction of tunnels
(Drilling and Blasting)
IS:6926-1973 - Code of practice for Diamond core drilling for site investigation for
river valley projects
IS: 4081-1967 - Safety code for blasting and related drilling operations
IS: 4138-1967 - Safety code for working in compressed air
IS: 4756-1968 - Safety code for tunnelling work
1.8.3 Submittals and Approvals
The Contractor shall obtain the prior approval of the KSEB or the KSEBs representative
for the following points of work execution, based on a comprehensive series of
submittals.

Design and drawings

Method of Application, sequence of grouting and pattern of grouting
Materials certificates: Admixtures, cement, sand and water
Drilling equipment and methods (including safety standards)

1.8.4 Deliverable Documents

As built drawings.
1.8.5 Boards other requirements
Consolidation grouting, shall be provided wherever required in the tunnel as per IS:
6066, IS: 5878 either as approved or as directed by the KSEBs Representative. Design
requirements shall be discussed from time to time at site between the contractors and
the KSEBs Representatives to reach a consensus of agreement.
The Contractor shall design and execute crown void and contact grouting in the tunnel
as per IS:6066 subject to approval of the Boards Representative. Daily records shall be

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maintained as per in IS: 6066. Reports shall be prepared at regular intervals to

summarise important observations and data as per IS: 6066.
Washing, testing of holes, surface preparation, injection, control of grouting operation etc
shall be carried out as per IS: 6066, IS: 5878, IS:11293 and as approved or directed by
the Board's Representatives. The drilled core samples shall be preserved.
Drilling equipments, grouting system arrangement, general requirements of grouting
equipment shall be as per IS: 6066.
1.8.6 General
All drilling operations shall be carried out, by fully qualified personnel using only
recognized modern methods and equipment. Drilling mud or lubricants shall not be
used, unless approved by KSEB.
Where drilling is to be performed through concrete, suitable pipes shall be installed prior
to casting. If pipes have not been provided, the reinforcing bars shall be located before
the drilling is commenced.
1.8.6

Drilling

1.8.6.1 Percussion Drilling

Percussion Drilling may be used for drilling of holes for rock dowels, bolts and anchors,
shallow area and contact grouting, drainage and for investigation purposes.
1.8.6.2 Rotary Drilling
Rotary Drilling shall be carried out with or without coring.
For rotary drilling with coring, double core barrels giving core diameters of at least 52
mm shall be used. The equipment shall be capable of drilling holes in any direction to a
depth of at least 300m. The radial deviation of boreholes shall not exceed 5% of the
borehole depth.
Wherever necessary, and as approved by KSEB, drill holes shall be provided with
casings through overburden and in rock of poor quality. The length through overburden
may be drilled without coring. Filling of part of the hole with grout and subsequent redrilling shall be carried out as necessary in zones of poor rock quality.
In specific case, as approved by KSEB, drill holes shall remain open. In those cases the
upper end of the hole, and the part of the hole extending through the overburden, shall
be provided with a pipe closed by a cap.
During drilling with coring, the rotation speed, feeding pressure and amount of flushing
water shall be adopted to the rock properties, so as to obtain cores of the best possible
quality.

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Cores shall be placed in core boxes of wood or metal. The depth of each run shall be
noted in the box and core losses marked by pieces of wood of corresponding length.
The core boxes shall be transported to and kept in a core store.
The water levels in the drill holes shall be measured when first encountered and at the
beginning and end of each shift. An electrical device, including spares, shall always be
available for this purpose.
Records of core drillings shall be submitted on daily basis within 24 hours and shall
comprise:
- core recovery per run, as well as all core losses, Rock Quality Designation and
fracture spacing
- depth of each run
- water level in the drill hole when encountered at the beginning and end of the
shift
- length of casing, lengths grouted and re-drilled.
The form of the record shall be as agreed with the KSEB.
1.8.7

Preparation of drill holes

1.8.7.1 General
All works in this section shall be carried out by fully qualified and experienced personnel.
1.8.7.2 Washing of Drill holes
All holes drilled for grouting and drainage, as well as for rock dowels, bolts, anchors,
etc., shall be washed after completion of drilling and prior to water pressure tests during
drilling, whenever such tests are to be performed.
Washing of holes shall be carried out by flushing, alternately with compressed air and
water under pressure, through pipes or stiff hoses equipped with swivel nozzle reaching
the bottom of the holes. Normally, flushing shall commence at the bottom and proceed
towards the mouth of the drill hole. Finished drill holes shall be properly plugged.
1.8.7.3 Pressure Testing of Drill holes
Water pressure testing of drill holes for investigation purposes, and in special cases for
placing of dowels, bolts, anchors, etc. shall be performed during drilling or after
completion thereof. The minimum inner diameter of the water conduit shall be 12 mm.
Testing, shall be made by means of single or double type packers, spaced up to 5 m
apart. Suitable packers for testing of holes of all occurring diameters shall be available
at all times. Packers which are used in weak rock shall be inflatable and have a length
of at least 500 mm.

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During testing, the water pressure shall be kept constant over three consecutive twominute periods and the water leakage shall be measured during each of those periods.
Testing for investigation purposes will be required at four different pressure levels
comprising 50, 100, 150, 200 % of the total overburden pressure. Normally, testing of
grouting holes shall be performed in one stage at a pressure level of 10 kg/cm 2. All
gauges used should be such that the pressures adopted are around the middle of the
measuring range of the gauge.
1.8.8

Grouting

1.8.8.1 General
The contractor shall submit to KSEB a method statement, giving full details of the
grouting systems, the contractor proposes to use.
All grouting operations shall be carried out by fully qualified and experienced personnel
and shall take account of the results of the grouting trials in terms of pressure, mix
design, hole spacing and depths.
All equipment for mixing and injecting grout shall be furnished by the contractor. The
equipment shall be maintained in good operating conditions at all times and comprise:
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double acting slush pumps capable of operating at a discharge pressure of at

least 2.5 MPa (25 kg/cm2)

high speed mixers, capable of preparing a colloidal form grout.

Mechanically agitated sumps with arrangements for screening and removal of

particles not passing a 1.2 mm U.S. Standard sieve or equivalent and with a
capacity corresponding to not less than three batches of grout, each of minimum
50 liters.

necessary valves, scales, pressure gauges and meters, packers, pipes, hoses,
fittings, spares etc.

adequate supply of air and water at a pressure of 0.6 MPa (6 kg/cm 2) for washing
of holes and crevices, pressure testing and grouting.

The grouting materials and equipment shall be adequately protected against rain and
sunshine. Grout supply conduits shall have an inner diameter of about 12 mm.
1.8.8.2 Grouting Requirements and Methods
Grouting may be required as area grouting to seal and consolidate, shallow parts of
foundation rocks, to produce a screen of tight rock in connection to plugs in the tunnels
and as contact grouting to seal joints in structures or areas between structure and
foundations. Pre-grouting of rock surrounding the tunnels may also be required before
excavation of portions where exceptional amounts of water leak is expected.

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Grouting may normally be required, of complete drill holes in one operation, or if special
circumstances so require of portions of drill holes down to two metres in length.
Grouting of portions of holes may be required in ascending or descending steps or
stages.
Where grouting in descending stages is prescribed, the grout holes shall be drilled down
to indicated depth, washed and pressure tested and grouted by means of a suitable
packer placed at the upper end of the portion to be grouted. The suitable time for
redrilling or water flushing of the drill hole after grouting will be determined on the basis
of experience gained on the setting time of the grout mix used. Water flushing of drill
holes in lieu of redrilling may be used subject to the approval of KSEB.
Where grouting in ascending stages or of complete holes is prescribed, the holes shall
be drilled to full depth, washed, pressure tested and grouted by means of a suitable
packer, placed at levels as approved by the KSEB. On grouting of the final stage, the
packer shall remain in place for a period of time to be approved by KSEB.
Normally, grouting in ascending stages will be required whereas grouting in descending
stages will be applicable in rock with high water losses.
Contact grouting shall normally be carried out by means of pipes for grouting and for
release of air. The pipes shall be installed before concreting.
Grouting of rock dowels, bolts, anchors, etc. is dealt in separate clause.
1.8.8.3 Materials
Cement grout shall be composed of the following ingredients, which may be used in
varying combination:
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Portland cement type I meeting the requirement of Indian Standard or other

Standard approved by the KSEB. The cement shall be free from lumps.

Clean water, according to clause 1.9.7.3.

well graded sand passing a 0.30 mm sieve, the percentage by dry weight
passing the 0.074 mm sieve should be less than 5.

additives in accordance with the manufacturers instructions.

bentonite with a liquid limit not less than 400%. Bentonite shall be pre-mixed
with 14 to15% of water and aged for at least two hours before adding to the grout
slurry.

Tests to establish the composition of the grout shall be carried out by the contractor as
approved by KSEB before the grouting operations start. Different grout mixed shall be
prepared in full scale using the grout mixes, and samples shall be extracted for checking
of segregation, hardening etc. Similarly, samples shall also be extracted from time to
time during the grouting works, as agreed with KSEB.
1.8.8.4 Procedure

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Grouting shall normally be preceded by a few minutes of pumping water into the holes,
where pressure tests give small water losses, grouting shall commence with a thin mix.
In holes with large water losses, a thicker mix shall be used. The water content of the
mix shall be adjusted so that, the grouting pump is operating at normal and practically
constant speed, irrespective of the permeability of the grouted rock. The water-cement
ratio shall be decreased, if necessary, reach the required pressure. If, however, the
pressure tends to rise excessively, the water cement ratio shall be increased; and
periodic injection of water under pressure as approved by KSEB may be carried out to
counteract premature stoppage. Under no conditions shall the grouting pressure or the
rate of pumping be allowed to increase suddenly. Sudden increase in rate of pumping
may indicate a heaving of the ground under the influence of the grout pressure.
Grouting in a given hole shall normally continue until either no grout is taken at 75 per
cent of the maximum pressure permitted by KSEB or less than 10 liters of grout is taken
per 5 minute period at the maximum pressure. The water-cement ratio by weight of the
grout shall normally not exceed 5. Holes, which do not take grout, shall be filled with
mortar.
If so required for the performance of continued grouting, open fissures through which
grout percolates to the ground surface shall be caulked using lead wool, mortar or other
approved packing.
Grout wastes and loose material shall be removed from foundation surfaces, which are
to receive concrete.
1.8.8.5 Records
Records, the format of which shall be as agreed with the owner, shall be submitted daily
to the owner and shall give all relevant data such as:-

Location and depth of holes and stages

Water losses measured during drilling and Lugeon values determined during
water pressure tests

Grout composition used, pressure and grout intakes for each stage

Possible rock heaving recorded.

The owner shall acknowledge sufficiency of records, 24 hours at the latest after receipt
of the same.