WO2022182934A1 - A sustainable two-component annular grout composition and method for grouting a tunnel annulus - Google Patents

A sustainable two-component annular grout composition and method for grouting a tunnel annulus Download PDF

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Publication number
WO2022182934A1
WO2022182934A1 PCT/US2022/017810 US2022017810W WO2022182934A1 WO 2022182934 A1 WO2022182934 A1 WO 2022182934A1 US 2022017810 W US2022017810 W US 2022017810W WO 2022182934 A1 WO2022182934 A1 WO 2022182934A1
Authority
WO
WIPO (PCT)
Prior art keywords
slurry
fluidized bed
silicate
sodium silicate
ash
Prior art date
Application number
PCT/US2022/017810
Other languages
English (en)
French (fr)
Inventor
Michael Mcdonald
Kelly Paul Short
Kenneth A. Berg
Flavio Ernesto Ribeiro
Jim Moran
Peter MARINESCU
Daoping GUO
Original Assignee
Pq, Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US17/588,942 external-priority patent/US11673835B2/en
Application filed by Pq, Llc filed Critical Pq, Llc
Priority to EP22710836.2A priority Critical patent/EP4298073A1/de
Publication of WO2022182934A1 publication Critical patent/WO2022182934A1/en

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/006—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing mineral polymers, e.g. geopolymers of the Davidovits type
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00663—Uses not provided for elsewhere in C04B2111/00 as filling material for cavities or the like
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00724—Uses not provided for elsewhere in C04B2111/00 in mining operations, e.g. for backfilling; in making tunnels or galleries
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/70—Grouts, e.g. injection mixtures for cables for prestressed concrete

Definitions

  • the present disclosure relates to the field of boring and, more particularly, backfilling the annular gap space created by a tunnel-boring machine as it advances through the ground.
  • Tunnels like those found for subways, automobiles or large diameter pipes are typically constructed using a tunnel-boring machine.
  • the tunnel boring machine offers several advantages in tunnel construction and is usually the only acceptable tunnel construction method in dense urban areas. Most often, the use of a tunnel boring machine is the most cost effective method.
  • Component “A” or the cement slurry is prepared above ground in a mixing station.
  • the solids content of the slurry varies but typically range from 30 to 40% by weight with the majority of all of the solids coming from ordinary Portland cement.
  • a minor amount of aluminosilicate material such as fly ash can be added to the slurry to help lower cost, improve sustainability and can be used to extend gel times. Fly ash volume must be kept as a minor component to avoid unacceptable loss of compressive strength and excessively long gel times.
  • the cement-based slurry may be pumped several kilometers before reaching the tunnel boring machine face. This requires the slurry to have a low viscosity and be resistant to solids settling (i.e. bleeding). As it is common for the tunnel boring machine to have downtime for repair and maintenance, the slurry must be resistant to chemical and material change over a 24 to 72 hour period.
  • Component “B” or accelerator is mixed with the cement-based slurry just prior to placement into the annular space.
  • Component “B” is usually an approximately 3.2 ratio sodium silicate.
  • the typical dosage rate of sodium silicate to cement slurry is approximately 5 to 10% wt/wt per hardened material.
  • Ordinary Portland cement has several outstanding material properties but has inherent deficiencies in brittleness, durability, adhesion to rock and metal as well as acid and fire resistance. Of increasing concern is the sustainability of using ordinary Portland cement due to its massive carbon footprint. Annual production of cement produces approximately 8% of global anthropogenic CO2 emissions and consumes approximately 2-3% of the global energy supply.
  • aluminosilicate powders such as Class C fly ash, Class F fly ash, ground granulated blast furnace slag, pumice and metakaolin can be reacted with an alkali source such as sodium silicate and/or sodium hydroxide as well as their potassium counterparts to create a cement alternative.
  • alkali source such as sodium silicate and/or sodium hydroxide as well as their potassium counterparts to create a cement alternative.
  • These cement alternatives are referred by different names including geopolymers, inorganic polymers, and alkali-activated aluminosilicates, among others.
  • These materials offer a much lower carbon footprint and better sustainability compared to ordinary Portland cement. Sustainability is higher if the alkali-activated aluminosilicate material is formulated with a by-product material such as fly ash generated from burning of coal for power generation or slag from the steel making process.
  • fly ash and ground granulated blast furnace slag are no longer viewed as waste material but as valuable products for cement blends and geopolymers.
  • fluidized bed coal ash differ considerably from class C & F fly ash obtained from pulverized coal combustion.
  • Class C & F ash is produced from burning bituminous and subbituminous coal at high temperatures ( ⁇ 1300°C - 1700 °C).
  • the resulting ash is spherical with a glassy, amorphous structure.
  • Fluidized bed coal ash typically uses a low grade coal ash and is burned at 800°C - 900°C where limestone or dolomite form part of the bed. As well as improving combustion efficiency, the limestone or dolomite acts as a sorbent for sulfur emissions from the coal or other fuel sources.
  • the resulting ash is a crystalline, irregular shaped powder.
  • Fluidized bed combustion ashes are variable in their chemical composition as well as the shape, size and surface area of the ash material. If limestone is used as the bed material the calcium levels as CaO can range from -10% to 40% by weight of the ash material. Properties of fluidized bed combustion ash are impacted by the source of fuel which is typically coal but also biomass such as wood and agriculture waste.
  • JP 6719154 discloses a low-calcium fluidized bed combustion ash solidification method, in which low-calcium fluidized-bed combustion ash is added to an active filler and an alkaline solution and kneaded, and cured. The resulting product is described as a solidified geopolymer.
  • the geopolymer described in JP 6719154 would have suitable compressive strength to be used as an annular grout material. However, the time to form the geopolymer at ambient conditions precludes the use of such a geopolymer as a two-component annular grout.
  • the current invention uses a fluidized bed combustion ash with greater than 10% CaO coal ash as the aluminosilicate source.
  • the initial reaction is not a geopolymerization reaction but rather involves the reaction of alkali silicate with sufficiently available calcium in conjunction with the particle characteristics of the fluidized bed combustion ash.
  • the irregular shape and porosity of the fluidized bed combustion ash also allows suitable slurry properties.
  • the invention results in a quick setting grout that permanently fills and seals the annular gap between the tunnel boring machine and the ground.
  • Slurry and material properties can also be adjusted by increasing/decreasing solids level and/or adjusting mixing procedures (i.e. high shear vs. low shear mixing). Similar to cement-based grouts the slurry properties can also be adjusted with admixtures such as retarders and superplasticizers, among others.
  • composition and method provides a much lower carbon footprint over current grout technology based on cement.
  • the composition can be made and run using existing equipment and set-up commonly used with existing two-components grouts based on ordinary Portland cement.
  • a grout composition for filling a tunnel annulus which comprises a slurry of fluidized bed combustion ash; and an aqueous alkali metal silicate.
  • the aqueous alkali metal silicate can be either sodium silicate and/or potassium silicate.
  • the aqueous alkali metal silicate is sodium silicate and the concentration of the sodium silicate rangers from 5 - 20 wt%.
  • the fluidized bed combustion ash includes calcium hydroxide.
  • the grout composition can further include ordinary Portland cement and/or metakaolin.
  • the grouting of a tunnel annulus is performed by mixing a slurry of fluidized bed combustion ash and an aqueous alkali metal silicate, and immediately applying that mixture into a tunnel annulus.
  • Figure l is a schematic representation of a tunnel boring machine and the annulus created thereby.
  • the present invention provides a method and composition for backfilling the annular gap surrounding a tunnel produced by a tunnel boring machine.
  • Fluidized bed coal ash that can be used for the compositions and methods for this invention are generated from the burning of coal and/or biomass or waste.
  • the preferred fluidized bed coal ash is crystalline and contains at least 10% calcium oxide.
  • These fluidized bed coal ashes are commercially available in large quantities as by-product from power generation. It is apparent that other types of fluidized bed ash generated from other sources such as agricultural waste or wood can be potential sources of material.
  • the fluidized bed coal ash is made into slurry using water.
  • Bentonite can be added to the water to improve suspension properties and prevent solids from settling.
  • Bentonite is typically used with cement-based grouts for improved rheology characteristics.
  • suitable suspension agents include polysaccharide-type viscosifiers such as guar gum, welan gum or xanthan gum, as well as other commonly used synthetic viscosifiers such as polyacrylates.
  • the slurry properties can be further improved via the addition of certain admixtures such as retarders and dispersants. These type of admixtures are commonly used in cement-based grouts to improve performance.
  • the slurry is set using a water-soluble alkali silicate.
  • Soluble silicates are produced with varying degrees of alkalinity as measured by the ratio of S1O2 to MeiO where Me is the alkali metal and is most commonly sodium or potassium.
  • Table 1 lists several grades of alkali silicate made by PQ Corporation that can be used for this application.
  • sodium silicate is the preferred form of alkali silicate for reasons of cost. For cost and to reduce hazardous exposure to high alkalinity, higher ratio sodium silicates have the advantage over low ratio silicates.
  • the preferred sodium silicate is a low ratio sodium and/or a higher ratio sodium silicate that is combined with sodium or potassium hydroxide.
  • a fluidized bed coal slurry is compared against similar formulated slurries using a range of aluminosilicate powder sources set forth in Table 2 below.
  • the class F and C fly ash meet ASTM C618 requirements for use in “Standard Specification for Coal Fly Ash and Raw or Calcined Natural Pozzolan for Use in Concrete” and ground granulated blast furnace slag conforms to ASTM C989, “Standard Specification for Slag Cement for Use in Concrete and
  • the first set of tests evaluates initial slurry viscosity and then viscosity at 24 hrs using ASTM D6910 (Marsh® Funnel). Later examples determined “Marsh seconds” using a Coulette rheometer and measuring the viscosity at a shear rate of 1000 s 1 . The viscosity reading is converted to “Marsh seconds” using the indicated equation
  • the slurry is mixed with N38® grade of sodium silicate, a widely used grade of sodium silicate for cement based grouts.
  • concentration of the sodium silicate can range from approximately 5% to 20% weight to weight of hardened material.
  • Gel times are measured by rapidly stirring the mix and recording the time when the mixture rapidly develops viscosity. Compressive strength is measured according to ASTM Cl 09.
  • Component “A” was formulated according to Example 1 and set forth in Table 2 above.
  • Component “B’ was changed to evaluate the impact of different sources of alkali on the setting and material properties when combined with Component “A”.
  • Example 2 compares the commonly used N®38 grade of sodium silicate with 8 M NaOH, 2.64 M NaOH,
  • Example 2 demonstrates suitable gel times and compressive strength properties can only be achieved using sodium silicate vs. sodium hydroxide or a mixture of sodium silicate and sodium hydroxide.
  • Example 3 demonstrates that minor additions of calcium hydroxide, calcium sulfate dihydrate (gypsum) or ordinary Portland cement.
  • gypsum calcium sulfate dihydrate
  • Other sources of aluminosilicate such as ground granulated blast furnace slag and metakaolin may be added to the blend with no adverse effect.
  • the incorporation of these additives can also be used to adjust for the variable nature of fluidized bed combustion ash. In the case of gypsum it was noted that it had a thinning effect on viscosity.
  • Ordinary Portland cement can be incorporated as a minor component to shorten gelation times and further improve compressive strength.
  • Tables 5a and 5b look at the impact soluble sources of calcium, ordinary Portland cement (OPC) and metakaolin and ground granulated blast furnace slag (GGBFS) on slurry properties, such as gelation time and compressive strength. These materials were added at a concentration of 2.17% and 5% on a weight to weight basis with cement.
  • OPC ordinary Portland cement
  • GGBFS metakaolin and ground granulated blast furnace slag
  • Example 5 demonstrates that gel times can also be controlled by adjusting the volume of sodium silicate added to the slurry of fluidized bed coal combustion ash as a slurry of fluidized bed coal combustion ash blended with ordinary Portland cement.
  • the annular grout of the present invention is used in connection with a tunnel boring machine.
  • the properties of the grout such as strength at one hour and gel time are important characteristics for such a grout. There is a need for a quick gel time and relatively high strength at one hour to enable the progress of the tunnel boring machine in the tunneling process to proceed at a commercially acceptable rate.

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  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Engineering & Computer Science (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Geology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Environmental & Geological Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Lining And Supports For Tunnels (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
PCT/US2022/017810 2021-02-26 2022-02-25 A sustainable two-component annular grout composition and method for grouting a tunnel annulus WO2022182934A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP22710836.2A EP4298073A1 (de) 2021-02-26 2022-02-25 Nachhaltige zweikomponentige ringförmige vergussmörtelzusammensetzung und verfahren zum verguss eines tunnelrings

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US202163154134P 2021-02-26 2021-02-26
US63/154,134 2021-02-26
US17/588,942 2022-01-31
US17/588,942 US11673835B2 (en) 2021-02-26 2022-01-31 Sustainable two-component annular grout composition and method for use with a tunnel-boring machine

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WO2022182934A1 true WO2022182934A1 (en) 2022-09-01

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0419154B2 (de) 1982-07-17 1992-03-30 Emu Aa Enu Rooranto Dorutsukumashiinen Ag
KR101999297B1 (ko) * 2018-04-27 2019-07-11 군장테크놀로지(주) 순환유동층 보일러 애시를 이용한 토사터널용 그라우트재

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0419154B2 (de) 1982-07-17 1992-03-30 Emu Aa Enu Rooranto Dorutsukumashiinen Ag
KR101999297B1 (ko) * 2018-04-27 2019-07-11 군장테크놀로지(주) 순환유동층 보일러 애시를 이용한 토사터널용 그라우트재

Non-Patent Citations (3)

* Cited by examiner, † Cited by third party
Title
DUAN PING ET AL: "An investigation of the microstructure and durability of a fluidized bed fly ash-metakaolin geopolymer after heat and acid expo", MATERIALS AND DESIGN, vol. 74, 9 March 2015 (2015-03-09), pages 125 - 137, XP029150745, ISSN: 0261-3069, DOI: 10.1016/J.MATDES.2015.03.009 *
LEE JAEHYUN ET AL: "Effects of High CaO Fly Ash and Sulfate Activator as a Finer Binder for Cementless Grouting Material", MATERIALS, vol. 12, no. 22, 7 November 2019 (2019-11-07), pages 3664, XP055929146, Retrieved from the Internet <URL:https://www.mdpi.com/1996-1944/12/22/3664> DOI: 10.3390/ma12223664 *
PEILA, D.BORIO, L.PELIZZA, S.: "The behaviour of a two-component backfilling grout used in a Tunnel-Boring Machine", ACTA GEOTECHNICA SLOVENIKA, vol. 1, 2011, pages 5 - 15, ISSN: 1854-0171

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