CEMENTATION

By

IN STRENGTHENING
NILES

ROCK

E.

GROSVENOR*

*Department

of Mining,

Colorado

School

of Mines.

CONTENTS
Page

Introduction "ractical #ses &esearch ' or( 'or( at Clima) 'or( on Carlton Tunnel Surnrnar+ -i.liograph+ , *

2 ! 2$% 2$% 2$% 2!2 2!, 2!/

I00#ST&1TIONS
Figure Page

2. COTesafter cementing 2. Method of appl+ing mi)ture of 3ater, cement, Sile) and intrusion aid 5. Method of se3ing a roof 3ith steel ca.le ,. Diagram of "erfo &oc( -olting /. Diagrarn of Carlton tunnel

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INT&OD#CTION This paper is a re7ie3 of the e)perimental 3or( that has .een done at the Colorado School of Mines to find a material 3ith a high tensile .ond8 ing strength. It 3ill also re7ie3 other 3or( in the field of cementation around underground openings, and 3ill also discuss sorne of the e)peri8 mental 3or( .eing carried on .+ the Clima) Mol+.denum Compan+ at Clima), Colorado, and on the Carlton Tunnel near 0ead7ille, Colorado. Cementation in strengthening roc( around an underground opening has .een discussed for sorne +ears here at the Colorado School of Mines, .ut the pro.lem of using material 3ith high tensile strength seemed to .e the main 3ea( point. 0ast +ear 9. S. 1dnan, a graduate student in mining, 3as assigned the pro.lem of in7estigating the additi7e materials used in concrete to gi7e added strength in tension and compression. This 3or( 3as done on regular N: cores of #na3eep granite and Da(ota sandstone. The tensile strength of the cores 3as o.tained and then cemented hac( together using se7era; different t+pes of cementing ma8 terials. The cemented cores 3ere tested after 2, 5, !, and 24 da+s to o.tain the strength curing cur7es. The cores 3ere cemented and fit .ac( together .onding surface as sho3n in <igure 2. to gi7e a ma)imum

The cores 3ere allo3ed to dr+ in this position 3ithout adding an+ addi8 tional 3eights. The results 3ere 7er+ encouraging and 22. and are summari=ed in Ta.les 2

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1. Cores after cementing.

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TABLE

1
1 Day
Age ,2.65 /4.62 22.%! 52.5 ,6./ 2$.,5 2%., 25.% 2!.5 25.4

-ONDED TENSI0E ST&EN>T9 IN "SI O< >&1NITE CO&ES Type Cementing Agent "ortland Cernent I & -er+le) "ortland Cernent I & CaCl= "ortland Cernent Il "ortland Cernent & -er+le) "ortland Cernent "ortland Cernent ? "ortland Cernent I "ure Sodiurn Silicate Cernent Mortar "ortland Cernent I?

3 Day
Age 22.65 26/.! /6.4 /!.4 /5.$ 2%.2 ,6.! 24.2 ,%.5 2%.2

Da)"
Age 24%.5 2,4.6 22,.2$ %6.6 $,., /%.4 //.2 /2./ !$.! $2.6

28Day
Age

300.3
242.2 2!%./ 2,$./ 254.! 25%.2 222., 226.4 226.2 26/.6

In In

TABLE

II
1 Da)"
Age $$.! 2/.% ,2.5 5!.% ,2.6 5/.2 5!.% 2$./ ,!.% 24./ 2$.5 2!.!

-ONDED TENSI0E ST&EN>T9 IN "SI O< D1AOT1 S1NDSTOB*iE Type Cementing Agent "ure Sodiurn Silicate "ortland Cernent I & -er+le) "ortland Cernent III & -er+le) "ortland Cement 9C 'eld Crete Cernent Mortar "ortland Cernent I "ortland Cernent II "ortland Cernent I & CaCl= "ortland Cernent ? "ortland Cernent I? "ortland Cernent I D Ern.ecco
*Ne3 surface 3as Iormed ,

3 Day
Age 4/.!* !6.! !,.2 /$.4 /$.5 !5.2 /6.4 5,.6 /4./ 5,.6 2!.4 55.,

7 Dar
Age 2//.4 222.4 4/.! 42.5 46.! 44.5 $/./ /5.5 !/.$ $2.5 /$.2* ,/.2

28

Da)"
Age 255.!* 2,%.! 2,5.4 252.6 26!.6 262.% 262.! 266.6 %2.$ 44./ 46.6 //.!

I'~.G.'!\ 2'~ ,
5

CRAC$" "ILl#

FILLED &IT' ) CE*ENT

1. REINFORCING
2.DEAERATION TUBE 3.INJECTlON 4. LUG TUBE

"TlRRING DE(ICE

!."ILl#CA$E %.COC$ &IT' UNI' (ER"AL JOINT

*I#ING CONTAINER

<I>#&E 2. Method
Cop+right, Engineering

of appl+ing
& Mining

mi)ture

of 3ater,

cernent,
Co.,

Sile) and intrusion

2%/$. #sed 3ith

aid.

Eournal,

Mc>ra3F9ill

"u.lishing

permission.

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The e)perimental data sho3 that for the granite roc( used "ortland Cement T+pe I 3ith -er+le) additi7e attained an a7erage .onding 7alue of 566 psi in 24 da+s. It also sho3s that the porous t+pe sandstone roc( .onded 3ell 3ith sodium silicate and fairl+ 3ell 3ith "ortland Cement T+pe I 3ith -er+le). It is .elie7ed that additional e)perimentation 3ith "ortland Cement T+pe I 3ith -er+le) ma+ pro7e to increase the .onding on this t+pe material. "&1CTIC10 #SES The method of appl+ing the e)perimental data to actual underground pro.lerns 3ould .e sorne forrn of grouting. In <rance grouting has .een used in underground 3or( and in shaft sin(ing as far .ac( as 2442. It is felt that .+ using a cement 3ith a high tensile .onding strength as sho3n .+ la.orator+ 3or(, it 3ill .e possi.le to cement the fractured =one around an underground opening 3here other methods of support might not .e satisfactor+. Other methods ha7e .een tried 3here reinforcing .ars, rods, and ca.les ha7e .een cemented into drill holes and the+ are holding ground that ma+ ha7e failed if con7entional roof .olts 3ere used. Einar Troften, a Nor3egian mining engineer, introduced a method of roof se3ing 3here he tries to 3ea7e a continuous arch of roc( and cement o7er the opening. The method of appl+ing the mi)ture of 3ater, cement, Sili), and intrusion aid is sho3n in <igure 2. 1reas that ha7e .een .lasted do3n sho3 that the cement actuall+ 3ent out into the crac(s and had 3o7en the roc( together to reinforce and hold the roof. Mr. Troften originated the method of se3ing the roof 3ith steel ca.le. This s+stem has .een used for a.out se7en +ears 3ithout a failure. The method is sho3n in <igure 5. In S3eden, the+ ha7e de7eloped a method called "erfo &oc( -olting. It protects the .olt against corrosion and anchor s it throughout the holeo It is sho3n in <igure ,. This method does not reGuire a grout pump or an+ other special eGuip8 mento The cernent mortar is placed in the perforated tu .e and the tu.e placed in the holeo 1 reinforcing .ar is dri7en into the tu.e 3ith a chipping hamrner or a stoper. This method has .een tested and pro7ed in .oth S3eden and in the tunnels in Eg+ptHs mammoth 1s3an Dam proIect. The (e+ to success 3ith this s+stem lies in the method of forcing the rod into the cement mortar. 1 light3eight chipping hammer appears to .e more satisfactor+ than a stoper for putting the rods up through the cement. &ESE1&C9 'O&A &esearch 3or( in roc( cementation is .eing carried on at the Clima) Mol+.denum Compan+ and at the Carlton Tunnel near 0ead7ille.
'O&A 1T C0IM1:

The pro.lem at Clima) is to dri7e a main haulage drift through a faulted area. The present proI ected plans call for the slusher stations and

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AIR VENT PIPE '/s" OlA.

,,
CEMENT GUN (20 ATM.)

ROPE BETWEEN HOLES HANGS LOOSELY

<I>#&E 5. &oof se3ing in7ol7es these stepsB O- Drill hole 2 to 5 in. deep. K2L Insert 3ire rope. .3- Insert 7ent pipe. K,L Insert short pipe connected to grout8 ing pump. K/L Insert Sil e) plug, K$L >rout hole 3ith concrete gun at 3,, l.. pressure.
Cop+right, Engineering & Mining Eournal , Mc>ra3F9ill "u.lishing Co., 2%/$. #sed 3ith permission.

Five Steps to Pe !o Ro"# Bolti$%

/ ] \ .~
.
. ...
SAND

..........

.....

ClMENT

WATER

22

l. MI& A RICH PlASTIC MORT AR

2. FILL '(TH HALVES OF SlEEVE

5. TIE SlEEVES TOGETHER

~&7.)7JT;;; M,;8MMJ!.NM*JOPQMRiS.QiPPPQPQHPPPPPP
P ,. SLl)E SlEEVE INTO )Rlll HOLE *

<I>#&E Cop+right, Engineering

,. Diagram of "edo roc( .olting.

Eournal, Mc Cra389fll "u.lishing Co., 2%/$. #sed 3ith permission.

D Mining

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sections of the slusher drifts to .e located 3ithin the faulted =one. The faulted =one is highl+ fractured, 3et, and contains a considera.le amount of fine gouge material. Ordinar+ grouting methods 3ere tried and 3ere not satisfactor+, The+ ha7e used t3o other methods of dri7ing slusher sta8 tions in this area. One method is to .uild a .ul(head up ne)t to the face as soon as the muc( has .een remo7ed, and fill this area ne)t to the face 3ith concrete. 1s soon as the concrete has set, the+ drill through the con8 crete and .last the ne)t round. In sorne sections the+ ha7e .een a.le to gunite the face as soon as pos8 si.le after .lasting and in this manner the+ ha 7e .een a.le to hold the area. The first attempt to grout the face and sides of a slusher station 3ith cement plus -er+le) 3as partiall+ successful .ut not satisfactor+. The main pro.lem encountered 3as not from the cement8-er+le) material .ut from tr+ing to find a suita.le pac(er to hold the grouting pipe in the holeo The holes 3ere drilled using a 28inch diameter .it, .ut most of them ended up .eing an+3here .et3een 2 and $ inches in diameter due to the highl+ fractured condition of the roc(. 9oles 3ere drilled in the .ac( and si des roughl+ parallel 3ith the heading and a.out 26 feet in ad7ance of the face. The ma)imum distance out into the 3alls and top 3as $ feet. 1dditional test holes 3ere drilled in the face and 3ere grouted, using cement 3ith -er+le) additi7e. 1fter .lasting, the test sections in the face areas 3ere found to .e cemented. The .ac( did not .rea( up to the grouted holes and this area held until the area 3as co7ered .+ a hea7+ coating of gunite. The main heading that has intersected the fault is in a highl+ fractured =one. Se7eral tons of ore ha 7e .een remo7ed from this one spot and it is still ca7ing. 'hen tr+ing to spile through this area using 4 ) 4 tim.ers, the ends 3ere sheared off .+ the ca7ing material. 1 s+stem of grouting is .eing planned 3here.+ it is hoped that this area ma+ .e completel+ ce8 mented together. The method that 3ill .e used here is e)plained later. WORK ON CARLTON TUNNEL The Carlton Tunnel is an old railroad tunnel that 3as dri7en in the 2446Hs, and 3as later used for one83a+ automo.ile traffic. The tunnel is %,66 feet in length and at the present time it appears to ha7e a ca7ed section e7er+ ,66 to !66 feet. The ca7ed sections are 7er+ short, a matter of 22 to 2/ feet in length at the top of the tunnel. The tim.er is so rotten that it is failing .ecause of the dead 3eight of the ma8 terial resting on it in fractured or faulted =ones. 1fter the tim.er Iails, the ca7ing 3ithin the fractured or faulted =one progresses up3ard. 1 series of holes 3ere drilled a.o+e and along the sides of a ca7ed area and 3ere grouted 3ith cement 3ith -er+le) additi7e. 1s a result of this cementation, the Io. of spiling through this area appeared to .e much easier. 1reas 3ere chec(ed that had .een grouted and 3ere found to .e 3ell sta.ili=ed. The loose material and gouge 3ere cemented together into

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12

x 12

Timber

Lagging
5 8 8P Cond u I

Concrete

01
1!'

CarIton Tunne1 ScaIe 1" = 50'

<I>#&E

/. Diagram

of Carlton

tunnel.

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large .loc(s. This area 3as enlarged to the full si=e of the tunnel and has .een cemented .+ grouting a series of holes that ha7e .een drilled in the .ac( and sides. These holes are at %6T to the center line of the tunnel. This method appears to cement an arch of concrete and roc( around the tunnel in the fractured =ones. This cementing 3as done .ecause it 3as found that the tim.ers in these ca7ed areas 3ere ta(ing 3eight and 3ere crushing under the load. There has .een no 7isi.le e7idence of 3eight since this cementing has .een done. It is felt that roc( .olts 3ould not 3or( under t.ese conditions .ecause of the nature of the .ro(en material and the lac( of an+ solid roc( to anchor the .olts in the holes. In sorne sections of the tunnel that ha7e not failed, roc( .olts 3ill .e used to gi7e added support. S#MM1&U 0et me .riefl+ summari=e the 3or( on cementation for strengthening roc(. The onl+ t+pe of ground that 3ould 3arrant a program of cementa8 tion is one that is highl+ fractured. I2 the ground is laminated or in la+ers, con7entional roc( .olts 3ill, and are 3or(ing satisfactoril+. The addition of cement in the hole 3ith the .olt 3ill help to suppl+ a uniform anchor throughout the hole and 3ill still hold the la+ers together e7en if the roc( should fracture and .rea( a3a+ from the plate at the collar of the holeo Mr. TroftenHs roof8se3ing, 3ith the addition of the rods or ca.les ap8 pears to .e an ans3er to their highl+ fractured roc(, if the grout material is properl+ inIected. The 'ater3a+s E)perimental Station of the Corps of Engineers has .een e)perimenting 3ith grouting fine crac(s .et3een la+ers of concrete. The+ ha7e .een tr+ing to find a good grouting material and to find the proper 3ater8cement ratio. The 3ater8cement ratio the+ ha7e found to 3or( .est is appro)imatel+ the same as 3as found here at the Colorado School of Mines. The #nited States -ureau of Mines in a recent pu.lication, gi7es the results of their e)perimental 3or( on inIecting 3ater and oil into the strata a.o7e coal seams. The+ are no3 stud+ing the inIection of cementing materials and are using an Epo)+ resin that has a 7er+ high tensile strength. The 3or( at Clima) Mol+.denum Compan+ and the Carlton Tunnel in8 dicates that a s+stem of cementation using a high tensile strength cement 3ill definitel+ strengthen the roc( around an underground opening to a point 3here it is possi.le to mine safel+ in a highl+ fractured area. The use of reinforcing rods in the drill holes 3ith the cement 3ould at times ha7e a decided ad7antage. This s+stem that I li(e to refer to as controlle grouting can .e used to cement fractured ground around an underground opening, seal off inflo3s of 3ater into tunnels, consolidate material around shafts, seal the area around an underground e)ca7ation that ma+ .e used to store compressed air or natural gas, to sta.ili=e sections of high3a+ tunnels, and possi.l+ help to sta.ili=e the slopes around large open pits,

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1dnan, 9. S., 2%/$, In7estigation of cementation of N: cores of #na3eep granite and Da(ota sandstone and their resultant tensile .onding strengthsB MasterHs thesis 454, Colorado School of Mines. 1ustin, C. c., 2%/5, &oof se3ingB Eng. and Min. Eour., 7. 2/,, no. %, p. %2. Mai=e, E. &., and 'allace, E. E., 2%/$, Cementation of .ituminous coal mine roof strata, "art 2B #.S. -ur. Mines &ept. In7. /56,. Troften, Einar, 2%/$, In Nor3a+ itHs roof se3ingB Eng. and Min. Eour., 7. 2/!, no. %, p.!4842. 'ater3a+s E)periment Station, 2%/$, "ressure grouting fine fissuresB Corps of Engineers, Tech. &ept. $8,5!. KOct.L #.S. 1rm+,