1. business and industrial
2. chemicals industry
3. adhesives

MICROFINE CEMENT GROUTS &
APPLICATIONS IN GROUTING
PRACTICE
Dr. A. V. SHROFF
Professor Emeritus,
M. S. UNIVERSITY OF BARODA.
CWC Lecture at Madras 25-03-2015
1
Scope of Presentation
Design & Characterization of Micro fine
cement grouts under static and dynamic
loadings.
Applications of Micro fine Cement grouts
at projects.
2
Need for Microfine Cements
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Suspension grouts, prepared conventionally with
ordinary Portland cement, can be successfully injected
into gravels and coarse sands.
Chemical grouts can permeate fine sands and coarse
silts, but they are expensive and pose environmental
and health problems.
As an alternative to chemical grouting of fine sands &
coarse silts, the use of grouts prepared with microfine
cements has been proposed.
The first microfine cement available commercially was
MC-500, manufactured by Onoda Cement Corporation
in Japan.
3
Microfine Cement Definitions
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ACI Committee 552, Geotechnical Cement Grouting,
defines microfine cement as a material in which
dmax <15 μm (Perretet al., 2000).
According to the European Standard for grouting
(SFS-EN 12715), microfine cements are characterized
by a specific surface area >800 m2/kg and
d95 <20 μm.
The Norwegian proposal divides two groups of
microcements: d95 <30 μm, microfine cement and
d95 <15 μm,ultrafine cement (Tolpannen& Syrjanen,
2003).
In U.K. practice, ultrafine cements are characterized
4
by dmax ≤ 6μm (Littlejohn, 2003).
Composition of Suspensions
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Water to Cement (W/C) Ratio (by weight):
Thick suspensions (W/C →0.7:1 -<2:1)
Thin suspensions
(W/C →2:1 –12:1 in research)
(W/C →2:1 –4:1 in applications)
Admixtures :superplasticizers (their use is
necessary for fluidity increase, according to
Bremen, 1997 & Saada, 2003), dispersants,
retarders, accelerators
Additives : bentonite (improves stability),
slag, silica fume, sodium silicate, fly ash
5
KIND OF SOIL
MicrofineCement
grouts
COHESIVE SOIL
GROUTED FORM
FRACTURING
SANDY SOIL
PERMEATION
GRAVEL
BOUNDARIES
INCREASE BEARING
STRENGTH
PREVENT
HEAVING
ROOFING
PREVENT
SETTLEMENT
SEAL WATER
ENSURE
AIR TIGHTNESS
PREVENT
SEEPAGE
6
Specific Applications
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Water sealing of dam bottom ducts
Water sealing of reservoir bottoms
Underground oil storage facilities
Preventing seepage of embankments on polder
dikes
Preventing seepage in reclaimed land
Preventing liquefaction of sandy soil
7
Specific Applications
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Curtain grouting for Dams and embankments
Ensuring leak tightness of retention dikes
around oil tank
Stabilization and sealing of work faces in shield
tunneling and pipe insertion work
Water sealing of joints on water and sewage
mains
Water sealing of tunnel walls
8
Specific Applications
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Preventing settlement of roads and
embankments to be constructed on weak
ground
Preventing heaving and boiling inside
cofferdams
Stabilization of soil in zones susceptible to
landslides
Remedying and preventing differential
settlement of oil tanks
Fixation and water sealing in fractured zone
during tunnel construction
9
Applications of MC Grouts
10
APPLICATIONS
DEPENDING UPON FRACTURING IN
THE ROCK NEAR SURFACE AT
FOUNDATION BED, SHALLOW
BLANKET GROUT IS PLACED ,
THROUGH WHICH A DEEP CURTAIN
GROUT IS INJECTED
.
CUTOFF IS EXTENSION OF CORE.
NO SEEPAGE PATH SHOULD BE AT
INTERFACE, AS IT IS CRICAL.
IN EMBANKMENT DAM WITH EARTH, USUAL POSITION RANGE FROM A
VERTICAL CURTAIN AT AXIS TO STEEPLY INCLINED ON ECOMMENCEING
1/3 OF THE WAY BETWEEN THE AXIS & U/S TOE OF THE DAM
CURTAIN AT FACED ROCKFILL DAM MAY COMMENCE FROM U/S TOE &
RANGE FROM A VERTICAL TOE AN INCLINED ORIENTATION.
IN GRAVITY DAM ,DRAINAGE & CURTAIN HOLES ARE COMMONLY DRILLED
FROM GALLERY WITHIN THE DAM
AT AN ARCH DAM THE CURTAIN MUST PASS THROUGH THAT PART OF THE
FOUNDATION WHICH REMAINS MORE OR LESS COMPRESSED DURING THE
FLEXURE CYCLE OF THE DAM
CLAY
CORE WALL
6-12M
EMBANKMENT DAM- EARTH CORE
BLNKET GROUTING
ROCK FILL DAM WITH CONCRETELINED FACE
DEEP GROUT CURTAIN
CONCRETE GRAVITY DAM
WITH INTERSECTING
FAULT ZONE
CONCRETE ARCH DAM
CONVENTIONAL CLOSURE
PATTERN FOR DRILLING &
GROUTING WITH SEQUENCE
11
APPLICATIONS
Microfine
cement
m
+sodium silicate
grout
Fan array from successive
heading
Fan array from successive heading
or from pit is designed for grouting
of rock fissures in crown portion,
preventing raveling down of siltsand during box jacking or tunnel
shielding operation as well as for
making crown impervious under
heavy seepage
Vertical parallel array of grout holes
are used to eliminate problems of
settlement of structures during
tunnel operation for subways or
Micro fine tube railway .
Cement+
Staggered array of grout holes rows
Sodium
Surface street level & fan hole from
silicate
within the tunnel downward to
grout
strengthen the soil in-between
tunnel bottom & top of sub ways
Parallel array from surface
Inclined array of grout holes
from pit
Micro fine grouts
12
Staggered array of grout
holes
Functions of Grouting
Grout
Grout
pipe
Permeation
Grout
Grout
pipe
Compaction
Grout
Grout
pipe
Hydro fracturing
13
Pore volume/pore
size reduction of
sand due to MC
grouting
Interaction
with
formation
14
Grouts

Classification
• Engineering Classification:
(based on grout characteristics & engineering performance
• Rheological Classification
d/dt = (1/  )(0 - p)
Binghamian:
Compressive/ Triaxial strength kPa
d/dt = (1/  )0
ST
Newtonian
Binghamian
Yield value (p)
Shear stress ( dyn/ cm2)
Viscosity  cps
Rate of shear d/dt Sec-1
Newtonian:
0.1
ZD
LI
IT
1
Time (Days)
10
100
15
Laboratory testing set-ups
1
2
Computerized Brookfield Rheometer
Time-viscosity
and
time-strength
relationship of cement, chemical and
cement based chemical grouts facilitates
initial flow and strength to resist
foundation stresses and washout forces
Servo-loop Material Testing System
1-Load unit
2- control unit
Load –deflection, t-strength curves
16
through load cell and transducers
Laboratory test set ups-Physical properties
(a) Marsh cone - fluidity
measurement afflux time
(b) Mud balance for
sp.gravity measurement
(c) Bleeding test under
pressure for stability
measurement
(d) Water- retentivity
meter for squeezed water
measurement
(e) Horizontal flow meter
for fluidity measurement
(f) Capillary viscometer for
viscosity measurement
(g) Bleeding potential
measurement of variable
depth of clear water above
sedimented cement flocs
(h) Washout test for the measurement of threshold gradient (Adherent strength) 17
Physical properties of MC grouts
W:C
Ratio
Physical Properties
Specific
Gravity
Gel
Time
min
Water
retentivity, s
Bleeding
Potential
Marsh
cone
viscosity
50 ml
100
ml
%
second
0.8
1.38
10
28
NM
Nil
31
1
1.19
13
24
NM
3%
28.5
2
1.14
180
18
49
8%
27.5
5
1.02
345
11
38
54%
27
NM: Not Measurable
18
INJECTION DEVICE
Column diameter: 2.2 –51 cm
Column length: 0.3 –18 m !!!
19
Device for Spherical Injections
The injection funnel represents 1/33 of a sphere and enables penetration depths
of approximately 75 cm.
20
Laboratory Injections
Aims:
•Injectability documentation
•Effectiveness determination
•Grouted soil design parameters (static &
dynamic loading)
21
GRAVEL
SAND
FINE
COARSE
0.006 mm
0.075 mm
0.425 mm
2 mm
4.75 mm
Penetrability of grouts w.r.t. formation material
COARSE SILT
MEDIUM
Towards
0.002 mm
SILT (NON PLASTIC)
FINE
CEMENT
D15/d85 should be between 5-24,
BENTONITE
D-soil,d-grout
Rock fissure size ≥ 3d, d-cement<0.1D10
POLYURETHANE AND POLYACRYLAMIDE
SILICATES – HIGH CONCENTRATION
SILICATES – LOW CONCENTRATION
D15/d85 > 40
AMINOPLAST
PHENOPLASTS
ACRYLATES
For Microfine
cement grout
(Shroff, Joshi-02)
ACRYLAMIDE
MICRO FINE
CEMENT
GROUT
22
Development of grouts - Micro fine cement grouts
MICRO FINE CEMENT GROUTS
POSSESS HIGH STRENGTH,
DURABILITY & PENETRATION
CAPABILITY COMPARABLE TO
CHEMICAL GROUTS WHICH
ELIMINATE TOXIC HEZARDS
MICRO GROUTS
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MC helper (dispersants):
1% Naphthalene
sulphonate- Gr I
1%Sulphonated melamine
Formaldehyde- GrII, III &
IV
GROUP-2
Slag+ Chemical activators
ROH,R2CO3,R2S,R2F- (0.1%)
Silica salts of R2O.(n)SiO2 type
where ‘ R’ is alkali metal ion Na,
K or Li
GROUP-3
MC-III + Chemical activators
(0.02 to 1%)as mentioned
above
(i) Specific
Surface area
9000
(cm2/g)
(ii) 50 percent
grain size
About 4
(μm)
100
% finer (cumulative vol %)

GROUP-1
Slag+ Portland Cement (As
Activator)
MC-I:25% slag+75% OPC
MC-II: 50% slag+50% OPC
MC-III:75% slag+25% OPC
Fineness
GROUP-4
MC-III+ Sodium silicate
(20,40,60,80%)
MC-III+Bentonite(1,2&3%)
MC-III+ Silica fume(4,12,20%)
90
80
70
60
MC
MCD-I
MCD-II
OPC(53 grade)
OPC(43 grade)
OPC(33 grade)
50
40
30
20
10
0
0.1
1
10
Particle size, mm x 10-3
100
1000
Fig-3.2 Particle size distribution curves of different cements from laser
particle size analyser
LASER PARTICLE SIZE ANALYZER
CHEMICAL COMPOSITION OF MCIII GROUTS
Oxides
Ca O
Sio2
Al2O3
Fe2O3
Mg O
SO3
%
49.2
29
13.2
1.2
5.6
1.2
1g
Loss
23
0.3
Development of grouts :Time- Viscosity of micro fine cement
 Trace amount of Na F in MCIII & Slag give low initial viscosity, controlled gel time, high
permeation & Low bleeding tends to solid mass at set time
MCIII with Sodium silicate in presence of 3% phosphoric acid proved to be best grout within
ideal frame work compared to OPC, MCD & other slag based grouts with activators & Silica fume.
GROUP 1
G
R
O
U
P
2
MC-I
MCII
MCI-25 %SLAG+ 75%OPC, MCII-50%SLAG + 50%C
MCIII + SODIUM SILICATE-20,40,60,80%
MCIII +60%
SODIUM
SILICATE
WITH PAPHOSPHORIC
ACID
G
R
O
U
P
3
ONLY SLAG + ACTIVATORS- 0.1 %
MC III( 25% S+ 75%C) ACTIVATORS .1%
MCIII+BENTONITE-1,2, & 3%
G
R
O
U
P
MCIII+ SILICA FUME- 4, 12, 20 %
4
B-BENTONITE
SF- SILICA
FUME
24
Development of cement & slag
Tri axial compression, UCS,
Grouts : Indirect Tensile & Flexural
SLAG+REACTANT
MCIII+REACTANT
strength
8000
UNCONFINED COMPRESSIVE STRENGTH
MCIII+SILICA FUME
MC-III
D
E
I
A
kPa
MCIII+SS
MC-II
W/S=0.8
%SS=40
28DAYS STRENGTH
7OOO V
6000 T
5000 O
R
MC-I
MCIII+BENT.
Ơ3=0
ơ3=98 KPA
Ơ3=196 KPA
4000 S
T
R
E
s
2000 s
MCD
3000
OPC
1000
0
0
1
2
3
4
% AXIAL
STRAIN
MCIII+ REC.
TYPICAL STRESS-STRAIN
CURVE OF RAW MC- SS
GROUT
SLAG+ REC.
MC-III
TRIAXIAL COMPRESSION
TEST
MCD
OPC
MCIII+SS
MCIII+SF
INDIRECT/FLEXURAL TENSILE STRENGTH
MC-III
MCIII+ BENT.
MC-II
MC-I
OPC
MCD
MCD
FAILED SAMPLES OF RAW
MC- BENTONITE
& MC-SILICAFUME ,UCS&
TRIAXIAL TESTS
Amongst cement & slag based grouts, MCIII (75% slag + 25% OPC )+Silica Fume grout with w:s ratio 2 show highest
deviator stress 8.2 M Pa with failure strain 4.66 % having maximum cohesion 750 kPa &  =610 with confining stress
196.2 kPa at 28days.
Slag & MCIII with reactants 0.1% Na F (Sodium Fluoride) display best raw unconfined compressive strength of 15
Mpa & Strength of grouted sand with these grouts show 7.32 Mpa. Adherent washout grouted sand Strength=6.83Mpa
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Also above grouts give highest indirect tensile 4.12 MPa & flexural strength 6.83 MPa of grouted sand at 28 days.
Creep measurement of
Cement & MC Grouted sand
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Creep Study : MC-SS & MC Grouted Sand
Creep of MC grouted sand increases Up to 42 days but the rate of increase
diminishes with progress of time. The creep of MC-SS grouted sand is more
compared to that of MC grouted sand. Creep of MC or MC grouted sand is 3to
6 fold that of ordinary concrete / mortar( cement –sand grout)
Cement based suspension grouts Exhibits low creep &most durable
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material among grouts
Cyclic Plate Load Test: Natural & MC Grouted Sand
Barken method of Natural Frequency of
foundation- soil system = √ CuA/ m,
m=Weight of machine & foundation, A=
contact area foundation &soil, Cu =
coefficient of elastic uniform compression
Ultimate load intensity obtained from load settlement curve of MC (W:C =5) grouted sand @ 28
days is 50 kpa which is 4.67 & 5.33 times in dry sand & 30 % saturated sand respectively.
After 10 cycles, in cyclic pile load test at 14 days Ei, Eh & coefficient of elastic uniform
compression (Cu) increased 1.31, 1.21 & 1.44 times respectively Ei, Eh, before grouting
= 44
28
& 77 kPa/mm ; Cu=65200kN/cubic meter
Settlement Damages due to liquefaction
Liquefaction
Saturated Sandy Soil without or with fines
Loss of Shear Strength
Reduced Effected Stress
Increased Pore Water Pressure
Earthquake forces give rise to liquefaction in soil that causes heavy
structure to sink substantially in to the ground or tilt excessively
and light weight structure to float upwards. The enormous damage
to number of Civil engineering structures in Kutch earthquake set
classical examples of earthquake induced liquefaction.
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Liquefaction Study – Microfine Cement Based Grouts
5
4
2
3
1
1 Loading frame
2 Pressure panel
3 Servo control
measuring unit
4 six channel
oscillograph & two
channel synchroscope
5 Actuator
Samples prepared by
dry pluviation or
compaction -temping
Standard vibration tri axial compression testing machine
SAMPLE- BEFORE & AFTER FAILURE
Consolidated undrained tri axial
cyclic compression tests are performed
TYPICAL TIME HISTORY OF CYCLIC LOADING
Initial liquefaction occurs when the
Value of pore pressure, generated in
saturated sand undergoing cyclic
undrained load ,momentarily equals
confining stress and effective stress
becomes zero. The strains during
each following Cycle become larger
with increase in cycles
In pure uniform sand under high ‘ƒ’
& C R R, pore pressure increased
Suddenly, reached 1 quickly, leading
to liquefaction while MC-grouted
mass took long time 210 s & MS-SS
30
350 s to reach initial liquefaction
0.75
0.65
|
|
|
|
|
|
|
UNSAFE |
|
|
|
|
0.55
0.45
UNSAFE
20
40
30
Liquefaction Study –
Microfine Cement Based Grouts
In thin grouts (w:c = 10 to
5 ) with 1 to 3% Bentonite,
CRR = 0.65to 0.50 while at
and above w:c = 2, CRR =
0 7to 0.85, virgin sand RD
= 0.3, CRR = 0.2 at Ni = 30
At 30 cycles CRR value of
MC-SS grouted sand are
above 0.6 at 1 day which is
within safe limit of
liquefaction. It is three
times than pure sand.
31
Design of Grouted Factor of Safety of a Soil
at Gandhidham – Hospital Building Site
(after earth quake)
Input data: moderately stiff uniform fine sand deposit. Earthquake
magnitude: 6.5, Seismic Energy source: 0.5km, amax peak =
0.998m/sec2 (from local seismic station),  = 20.2kN/m3, depth from
GL (z) = 5 mt, Sd = 1- 0.00765 z (Tyoud 2001) = 0.9617,
Induced CSR = 0.65(amax/g)(o/o’)Sd ,o =  h = 101 kPa, o’ = w h
=51kPa,
Induced CSR = 0.65*(0.998/9.81)*(101/51)*0.9617 = 0.1259
CRR from cyclic Tri axial test on virgin sand= 0.251at equivalent cycle
8.33, applying correction factor=0.642,
CRR corrected=0.251x0.642=0.161, F= CRR/CSR= 0.161/0.1259=
1.28 which is low, which is required to be increased
To increase FS of soil grouted with MCSS with w:c = 5 and SS = 20%,
CRR (at one day) = 0.81 at 8.33 cycles (above figure) applying same
correction factor Cr = 0.642, CRRc = 0.642*0.81 = 0.52, so, FS =
32
0.52/0.1259 = 4.1( Increase in FS 8 times)
Alccofine MicroMaterials
Stands With The Test Of Time
34
Alccofine Plant- Goa
Flash Dryer
MILL
SILO
AQP – Particle size Distribution
Alccofine1101
Sr.
Particle size
distribution
AQP
Results of
Alccofine1101
1.
D10
< 2.5µ
1.3
2.
D50
<6µ
5
3.
D90
<12µ
10.6
4.
D100
<26µ
20
Why Alccofine?

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We provide customized products as per site working
conditions
Open time is high as considering a delay in over all
grouting purpose
Customization can be done with respect to fineness , W/c
ratio required for grouting , strength criteria if any (
feasible of cement based grouts) and setting time.
Have tieup with applicators and Global Contractors
Exporting materials to Canada, Australia, Indonesia and
many more countries
Customization of packing if any required based on total
quantity required
Technical support and on site support for our customers.
38