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Experimental Study on Erosion and Viscous Fingering of Fresh Cement-Based Grout After Injection Stops
KTH, School of Architecture and the Built Environment (ABE), Civil and Architectural Engineering, Soil and Rock Mechanics.ORCID iD: 0000-0002-1195-1587
Luleå Univ Technol, Dept Civil Environm & Nat Resources Engn, Div Min & Geotech Engn, SE-97187 Luleå, Sweden.
KTH, School of Architecture and the Built Environment (ABE), Civil and Architectural Engineering, Soil and Rock Mechanics.ORCID iD: 0000-0002-8152-6092
Luleå Univ Technol, Dept Civil Environm & Nat Resources Engn, Div Min & Geotech Engn, SE-97187 Luleå, Sweden.
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2025 (English)In: Rock Mechanics and Rock Engineering, ISSN 0723-2632, E-ISSN 1434-453XArticle in journal (Refereed) Epub ahead of print
Abstract [en]

Grouting is widely used in tunnel construction as a measure to reduce water seepage through rock fractures. Fresh cement-based grout often comes into contact with flowing water after being injected into rock fractures, especially in post-excavation grouting scenarios in rock tunnels or pre-excavation grouting in deep tunnels and remedial grouting in dam foundations. The flowing water can cause erosion of the fresh grout and viscous fingering in the grout, which reduces the efficiency of the grouting. In the present study, experimental tests using a simulated fracture were carried out to investigate grout erosion and viscous fingering in the time period after the injection stops until the grout has gained sufficient strength. The aim of the tests was to evaluate the validity of the existing criteria used to determine grout erosion and viscous fingering. The test results showed significant grout erosion and viscous fingering caused by the flowing water despite these behaviors not being expected according to the existing criteria. The reduction in the grouted area was up to 50% after 10 min and up to 64% after 60 min. Based on these results, the mechanism of grout erosion and viscous fingering between water and grout is discussed with respect to grouting design strategy. The present study provides a deeper understanding of grout erosion and viscous fingering after the grouting is completed, indicating complex mechanisms of these behaviors and oversimplification in the existing criteria. The results are useful for the design of grouting in fractures with flowing water.

Place, publisher, year, edition, pages
Springer Nature , 2025.
Keywords [en]
Grouting, Cement-based grout, Grout erosion, Viscous fingering, Experimental study, Simulated fracture
National Category
Geotechnical Engineering and Engineering Geology
Identifiers
URN: urn:nbn:se:kth:diva-361630DOI: 10.1007/s00603-025-04486-9ISI: 001439862800001Scopus ID: 2-s2.0-86000670955OAI: oai:DiVA.org:kth-361630DiVA, id: diva2:1946961
Note

QC 20250324

Available from: 2025-03-24 Created: 2025-03-24 Last updated: 2025-07-10Bibliographically approved
In thesis
1. Cement-based grouting of rock foundations for new and existing dams
Open this publication in new window or tab >>Cement-based grouting of rock foundations for new and existing dams
2025 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Grout curtains are usually constructed under dams as a barrier to prevent leakage from the reservoir, reduce uplift, and also prevent transport of fine material through the foundation. These grout curtains have mainly been designed by using an empirical design approach. However, the empirical approach has its limitations, such as lack of design over grout curtain thickness, long grouting time as a result of the stop criterion, and high grouting pressure which can cause unfavorable jacking.

To deal with these limitations, a theory-based design methodology for grout curtains under new dams has been developed. The grout curtain is treated as a structural component in the dam foundation. The geometry and location of the grout curtain is firstly designed with respect to three requirements: (i) the hydraulic conductivity reduction, (ii) prevention of erosion of fracture infillings and (iii) optimization of uplift reduction. Grouting work is then designed to obtain the designed geometry of the grout curtain. In the design of the grouting work, analytical calculations are implemented to determine the grouting pressure, grouting time and grout hole layout. The erosion process of fracture infilling materials was studied as a supplement to the requirement (ii). Coupled numerical analyses were performed to better understand the initiation of erosion of fracture infillings. The results showed that a previous equation derived by White under laminar flow can be suitable to estimate the incipient motion of fracture infilling materials. 

For existing dams, remedial grouting is a measure to strengthen the deteriorated grout curtains under old dams. The major challenge of remedial grouting is the high pressure gradient in the previously grouted zones. High gradient leads to high water velocities, where the flowing water can erode the injected fresh grout in the rock fractures. Even if the fractures are sealed, a phenomenon called viscous fingering can occur, which destabilize the grout front and creates new leakage channels. Erosion of fresh cement-based grout and viscous fingering between water and grout were studied with experiments and numerical simulations. The experiments revealed that the existing criterion on grout erosion tends to be oversimplified. Viscous fingering was observed despite the theoretical prediction and the numerical simulations suggested it would not occur. This deviation was further discussed with respect to uncertainties in the experimental setup.

Strategies were suggested for remedial grouting practice using cement-based grout to minimize disturbance by flowing water: (i) utilize multiple pressure relief holes upstream of grout holes to reduce water-induced shear stress on the fresh grout; (ii) maintain sufficient pressure holding time to provide time for the grout to harden and prevent the displacement of the injected grout.

Abstract [sv]

Injekteringsridåer konstrueras vanligtvis under dammar som en barriär för att förhindra läckage från magasinet, reducera upptrycket, och även för att förhindra transport av finmaterial genom grunden. Traditionellt har dessa injekteringsridåer utformats med en empirisk dimensioneringsmetod. Denna metod har dock vissa begränsningar, såsom brist på dimensionering av injekteringsridåns tjocklek, långa injekteringstider till följd av stoppkriterier samt höga injekteringstryck som kan orsaka ogynnsam spricköppning (jacking).

För att hantera dessa begränsningar har en teoribaserad dimensioneringsmetodik utvecklats för injekteringsridåer under nya dammar. Injekteringsridån betraktas här som en strukturell komponent. Geometrin och placeringen av injekteringsridån utformas utifrån tre krav: (i) minskning av hydraulisk konduktivitet, (ii) förebyggande av erosion av sprickfyllnadsmaterial och (iii) optimering av reduktion av upptrycket. Injekteringsarbetet utformas sedan för att uppnå den planerade geometrin för injekteringsridån. Vid dimensioneringen av injekteringsarbetet används analytiska beräkningar för att bestämma injekteringstryck, injekteringstid och borrhålslayout. Erosionsprocessen för sprickfyllnadsmaterial studerades som ett komplement till krav (ii). Kopplade numeriska analyser genomfördes i projektet för att bättre förstå erosionens initiering i sprickfyllnadsmaterial. Resultaten visade att en tidigare ekvation, härledd av White under laminärt flöde, kan vara lämplig för att uppskatta när förflyttningen av sprickfyllnadsmaterial initieras.

För befintliga dammar är reparationsinjektering en åtgärd för att förstärka injekteringsridåer som över tid har försämrats. Den största utmaningen vid reparationsinjektering är den höga tryckgradienten i tidigare injekterade zoner. En hög gradient kan leda till vattenflöden med höga hastigheter, vilket kan erodera nyligen injekterat cementbaserat injekteringsbruk i bergsprickorna innan det härdat. Även om sprickorna tätas kan ett fenomen kallat viskös kanalbildning uppstå i det nyligen injekterade bruket, vilket destabiliserar injekteringsfronten och skapar nya läckagekanaler. Erosion av färskt cementbaserat injekteringsbruk och viskös kanalbildning mellan vatten och injekteringsbruk studerades genom experiment och numeriska simuleringar. Experimenten visade att den befintliga kriteriemodellen för erosion tenderar att vara alltför förenklad. Viskös kanalbildning observerades trots att teoretiska förutsägelser och resultat från numeriska simuleringar antydde att fenomenet inte skulle uppstå. Denna avvikelse diskuterades vidare, speciellt med hänsyn till ingående osäkerheter i den experimentella uppställningen.

Baserat på erhållna resultat föreslogs ett antal strategier för reparationsinjektering med cementbaserat injekteringsbruk för att minimera störningarna från strömmande vatten: (i) användning av flera tryckavlastningshål uppströms om injekteringshålen för att minska vattnets skjuvspänning på det färska bruket och (ii) tillräcklig tryckhållningstid för att ge injekteringsbruket tid att härda och förhindra förflyttning av den injekterade massan.

Place, publisher, year, edition, pages
Stockholm: KTH Royal Institute of Technology, 2025. p. 77
Series
TRITA-ABE-DLT ; 2512
Keywords
Grout curtains, rock grouting, dams, infilling materials in rock fractures, grout erosion, viscous fingering, remedial grouting, Injekteringsridåer, berginjektering, dammar, sprickfyllnadsmaterial, erosion av injekteringsbruk, viskös kanalbildning, reparationsinjektering
National Category
Geotechnical Engineering and Engineering Geology
Research subject
Civil and Architectural Engineering, Soil and Rock Mechanics
Identifiers
urn:nbn:se:kth:diva-366849 (URN)978-91-8106-298-4 (ISBN)
Public defence
2025-08-29, F3, Lindstedtsvägen 26, KTH Campus, public video conference link https://kth-se.zoom.us/j/69019536392, Stockholm, 14:00 (English)
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QC 20250711

Available from: 2025-07-11 Created: 2025-07-10 Last updated: 2025-10-29Bibliographically approved

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Zhang, SuihanJohansson, FredrikZou, Liangchao

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