600 Tu Etg 001 - 01

PROYECTO HIDROELECTRICO ALTO MAIPO
INGENIERIA BASICA
GENERAL SPECIFICATIONS FOR TUNNELLING

AND ROCK SUPPORT
19-12-08
PARA LICITACION
EMISION
FECHA
PROPOSITO DE LA EMISION
PREPARA
REVISO
COORDINADOR
GENERAL
APROBO
D. PROYECTO
/ D. ADJUNTO
APROBO
SUBGERENTE
DE INGENIERIA
APROBO
GERENTE DE
PROYECTO
APROBO
REVISION
1
N: 600-TU-ETG-001
600-TU-ETG-001
i
INDEX
ITEM
CONTENTS
PG.
1.
Drilling of holes, exploratory drilling and grouting ................................................. 1

1.1
Scope .................................................................................................................. 1
1.1.1
Coverage ............................................................................................................. 1
1.2
Classification and Definition ................................................................................. 1
1.3
Reference Standards ........................................................................................... 1
1.4
Submissions by the Contractor ............................................................................ 1
1.4.1
Documents........................................................................................................... 2
1.4.2
Test Reports ........................................................................................................ 2
1.5
General ................................................................................................................ 2
1.6
Equipment and Execution .................................................................................... 3
1.6.1
Exploratory Drilling and Grouting ......................................................................... 3
1.6.2
Holes for other Purposes ..................................................................................... 4
1.6.3
Drilling Accuracy: ................................................................................................. 5
1.6.4
Deviation Measurements of Drill-holes ................................................................. 5
1.6.5
Water Pressure Tests .......................................................................................... 5
1.6.6
Flushing between holes ....................................................................................... 5
1.6.7
Grouting ............................................................................................................... 6
1.7
Logging of drill holes ............................................................................................ 7
1.8
Water Pressure Testing ....................................................................................... 8
1.9
Grouting ............................................................................................................... 8
1.9.1
Grouting Materials................................................................................................ 8
1.9.1.1
Water ................................................................................................................... 8
1.9.1.2
Cement ................................................................................................................ 8
1.9.1.3
Admixtures ........................................................................................................... 9
1.9.1.4
Chemical grouts ................................................................................................. 10
1.9.2
Cement Grouting above ground ......................................................................... 10
1.9.3
Cement Grouting underground........................................................................... 11
1.9.4
Chemical Grouts ................................................................................................ 12
1.9.5
2.
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Filling of Cavities with Concrete or Mortar (Consolidation grouting) ................... 12
Rock Excavation ................................................................................................ 13
2.1
Scope and definitions ......................................................................................... 13
2.1.1
Coverage ........................................................................................................... 13
2.1.2
Classification and Definition ............................................................................... 13
2.1.2.1
General .............................................................................................................. 13
2.1.2.2
Rock Mass Quality Classification ....................................................................... 14
2.2
Submittals by the Contractor .............................................................................. 14
2.2.1
General .............................................................................................................. 14
2.2.2
Documents for submittal-Rock excavation ......................................................... 15
2.2.3
Test Reports ...................................................................................................... 15
2.2.4
Documents for submittal-TBM excavation .......................................................... 16
2.3
Rock Excavation ................................................................................................ 17
2.3.1
General Requirements ....................................................................................... 17
2.3.2
Ventilation .......................................................................................................... 20
2.3.3
Illumination, Communication and Roadways ...................................................... 21
2.3.4
Survey ............................................................................................................... 21
2.4
Open Cut Excavation ......................................................................................... 22
2.5
Underground Excavation.................................................................................... 22
2.6
Drilling and Blasting (Above- and Underground) ................................................ 23
2.6.1
General .............................................................................................................. 23
2.6.2
Excavation Tolerances ....................................................................................... 23
2.6.3
Drilling Accuracy ................................................................................................ 24
2.6.4
Perimeter Blasting.............................................................................................. 24
2.6.4.1
General .............................................................................................................. 24
2.6.4.2
Smooth Blasting ................................................................................................. 24
2.6.4.3
Pre-splitting ........................................................................................................ 25
2.7
Drilling and Reaming of Shafts by raise-boring machine (RBM) ......................... 25
2.8
Tunnel excavation by tunnel boring machine (TBM) ........................................... 25
2.8.1
General .............................................................................................................. 25
2.8.2
Requirements to TBM machines ........................................................................ 26
2.8.3
Backup system .................................................................................................. 28
2.8.4
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Exploratory drilling, grouting and rock support ................................................... 28
2.8.5
Invert concrete segments ................................................................................... 29
2.8.6
Assignment of risk during TBM excavation......................................................... 29
2.9
Utilisation of Materials ........................................................................................ 30
3.
Rock Support ..................................................................................................... 30

3.1
Scope ................................................................................................................ 30
3.1.1
Coverage ........................................................................................................... 30
3.1.2
Classification and Definition ............................................................................... 31
3.1.2.1
General .............................................................................................................. 31
3.1.2.2
Rock Mass Quality Classification ....................................................................... 31
3.1.2.3
Rock Support Classification ............................................................................... 31
3.2
Reference Standards ......................................................................................... 33
3.3
Submissions by the Contractor .......................................................................... 33
3.3.1
General .............................................................................................................. 33
3.3.2
Documents......................................................................................................... 33
3.3.3
Test Reports ...................................................................................................... 34
3.3.4
Certificates ......................................................................................................... 34
3.4
General .............................................................................................................. 34
3.4.1
Inspection of Tunnels, Marking of Chainage, Wash-down .................................. 34
3.4.2
Rock Support ..................................................................................................... 35
3.5
Scaling ............................................................................................................... 36
3.5.1
General .............................................................................................................. 36
3.5.1.1
Basic Scaling ..................................................................................................... 37
3.5.1.2
Additional Scaling .............................................................................................. 37
3.6
Rock Bolts and Accessories ............................................................................... 38
3.6.1
Materials ............................................................................................................ 38
3.6.2
Accessories ....................................................................................................... 39
3.6.3
Execution ........................................................................................................... 40
3.6.3.1
Drilling and Installation of Resin End-anchored Bolts ......................................... 40
3.6.3.2
Drilling and Installation of Fully Cement-grouted Bolts ....................................... 40
3.6.4
Testing ............................................................................................................... 41
3.6.4.1
General .............................................................................................................. 41
3.6.4.2
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Criteria for Assessment of Test Numbers and Acceptance of Test Results ........ 42
3.6.4.3
Measures to be taken in Case of Rejection and Re-bolting ................................ 42
3.7
Spiles ................................................................................................................. 43
3.8
Rock Anchors .................................................................................................... 43
3.9
Sprayed Concrete .............................................................................................. 44
3.9.1
General .............................................................................................................. 44
3.9.1.1
Composition ....................................................................................................... 44
3.9.1.2
Requirements for Sprayed concrete ................................................................... 46
3.9.1.3
Methods/Execution ............................................................................................ 46
3.9.1.4
Thickness .......................................................................................................... 47
3.9.1.5
Testing and Control............................................................................................ 47
3.9.1.6
Documentation ................................................................................................... 48
3.9.1.7
Reinforcement of Sprayed Concrete .................................................................. 48
3.9.1.8
Method/Execution .............................................................................................. 49
3.10
Cast in place Concrete Rock Support ................................................................ 50
3.10.1
Scope ................................................................................................................ 50
3.10.2
Materials/Equipment .......................................................................................... 50
3.10.2.1
Materials and Admixtures for Concrete .............................................................. 50
3.10.2.2
Reinforcement (if applicable) ............................................................................. 51
3.10.2.3
Concrete Grade and Strength Requirements ..................................................... 51
3.10.2.4
Methods/Execution ............................................................................................ 51
3.10.3
Tolerances ......................................................................................................... 52
3.10.4
Testing and Control............................................................................................ 52
3.10.4.1
General .............................................................................................................. 52
3.10.4.2
Production Control ............................................................................................. 52
3.10.4.3
Materials Control prior to Concreting .................................................................. 52
3.10.5
Documentation ................................................................................................... 53
4.
Investigation and Instrumentation during construction ........................................ 53

4.1
Scope ................................................................................................................ 53
4.1.1
General .............................................................................................................. 53
4.1.2
Coverage ........................................................................................................... 54
4.2
Reference Standards ......................................................................................... 55
4.3
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Submittals by the Contractor .............................................................................. 55
4.3.1
Documents......................................................................................................... 55
4.3.2
General .............................................................................................................. 56
4.3.3
Core Drilling and Water Pressure Testing .......................................................... 56
4.3.3.1
General .............................................................................................................. 56
4.3.3.2
Drilling Equipment .............................................................................................. 57
4.3.3.3
Core Boxes ........................................................................................................ 57
4.3.3.4
Measuring Equipment ........................................................................................ 58
4.3.3.5
Water Pressure Testing ..................................................................................... 58
4.3.3.6
Calibration Procedure ........................................................................................ 59
4.3.3.7
Programme of Work and Number and Position of Boreholes ............................. 59
4.3.3.8
Drilling ................................................................................................................ 59
4.3.3.9
Handling and Storage of Core Samples ............................................................. 61
4.3.3.10
Inclination and Orientation of Boreholes............................................................. 62
4.3.3.11
Backfilling .......................................................................................................... 62
4.3.3.12
Record of Operations ......................................................................................... 63
4.3.4
Services for Rock Mechanical Testing and Rock Stress Measurements ............ 64
4.3.5
Convergence Stations ........................................................................................ 64
4.3.6
Piezometers ....................................................................................................... 66
4.3.7
Surface Settlement Monuments and Fixed Points .............................................. 66
4.3.8
Joint Deformation Meters ................................................................................... 67
4.3.9
Ground Water Monitoring ................................................................................... 67
4.3.10
Materials ............................................................................................................ 67
4.3.11
Measuring Range............................................................................................... 67
4.3.12
Accuracy and Resolution ................................................................................... 67
5.
Pavement in Water Tunnels ............................................................................... 68

5.1
Specifications..................................................................................................... 68
5.1.1
Pavement in the access tunnel .......................................................................... 68
600-TU-ETG-001
vi
List of tables
Table 1-1:
Table 1-2:
Table 2-1:
Table 2-2:
Table 2-3:
Table 2-4:
Table 2-5:
Table 2-6:
Table 3-1:
Table 3-2:
Table 3-3:
Table 4-1:
Table 4-2:
Submittal of documents Drilling of holes ............................................................. 2

Submittal of test reports grouting ........................................................................ 2
Documents for submittal Rock excavation ........................................................ 15
Documents for submittal Blasting tests ............................................................. 16
Documents for submittal TBM excavation ......................................................... 16
Limits for peak particle velocity ............................................................................ 19
Limits for toxic gas levels ..................................................................................... 20
Drilling accuracy .................................................................................................. 24
Submittal of documents- Rock Support ................................................................ 33
Submittal of test reports Rock support .............................................................. 34
Test frequency ..................................................................................................... 53
Submittal of documents Investigation and instrumentation ................................ 56
Tolerances ........................................................................................................... 60
600-TU-ETG-001
1
1.
DRILLING OF HOLES, EXPLORATORY DRILLING AND GROUTING

1.1
Scope
1.1.1
Coverage
This Chapter specifies requirements for drilling of holes for ground water control
systems and all exploratory drilling, water pressure testing and grouting in order to explore and
modify the properties of the ground on or through which the Works are to be constructed. The
extent of such work depends on the properties of the soil and rock encountered during the
progress of the Works and shall be carried out as directed by Gener.
1.2
Classification and Definition
Definition of grouting at the face and grouting behind the face shall be similar to
the corresponding definition of support work in Chapter 3.1.2 Classification and Definition, under
definition of Support work at the face and Support work behind the face.
1.3
Reference Standards
The work shall be performed according to relevant standards, or if no standards

exist, the work shall be performed according to recognised practice approved by Gener.
1.4
Submissions by the Contractor

Submissions that the Contractor is required to make to Gener are described
below.
The issue time defines the date that Gener shall receive the first issue of the
documents:
XF = X number of weeks prior to start of manufacture/work as applicable.

XT = X number of weeks after completion of test/inspection/work as applicable.
600-TU-ETG-001
2
1.4.1
Documents
The Contractor shall prepare and submit documents in accordance with Table
1-1.
Submittal of documents Drilling of holes
Issue for Issue for
Documentation
Issue time
approval
info
Organisation plan for the Works showing procedures and
materials for the work and the responsibilities and
*
6F
qualifications of the personnel.
Table 1-1:
Log of all drilled holes.
Specific grouting procedures,

properties and equipment.
material,
composition,
1T
6F
Geners approval does not relieve the Contractor of his sole responsibilities for
efficient and successful execution of the work.
1.4.2
Test Reports
The Contractor shall make tests and prepare and submit test reports in
accordance with Table 1-2.
Table 1-2:
Item
Characteristics of grout agents
Characteristics of packers and flexible hoses
1.5
Submittal of test reports grouting

Issue for Issue for
approval
info
*
*
Issue time
6F
6F
General
Drilling of holes for exploratory drilling, ground water control and rock mass
grouting encompasses:
Drilling of vertical and inclined holes from surface for rock mass grouting in dam
foundation and control of ground water in areas as defined by Gener.
Drilling of holes for exploratory drilling and grouting from surface, from any tunnel
and cavern-front or from elsewhere in the underground openings at all angles as instructed by
Gener.
600-TU-ETG-001
3
Grouting works will be performed in underground constructions for control of
permeability, for consolidation and as contact grouting around or in structures in underground
openings.
Grouting may be done either as cement grouting or as chemical grouting.
Grouting operations are not designed and specified in detail at the tender stage.
The grouting works will be decided and designed by Gener in co-operation with the Contractor
during excavation.
The Contractor shall at any time during the progress of the Works provide and
maintain adequate equipment and materials with stand-by reserves to be able to carry out any
drilling and grouting operation covered in the specifications.
The grouting shall be supervised by an engineer with documented grouting and
drilling experience from similar works. At least one additional crew member shall document
appropriate experience.
The Contractor shall keep daily updated records and logs of all drilled holes,
flexible grouting tubes, water pressure tests and grout takes. The results shall be presented in
numerical and graphical format, comprising every borehole and every flexible tube with results
of water pressure tests, grout takes at the various depth intervals, and data for performance and
applied pressures. The boreholes and tubes shall be given a number, identifying location as
well as direction.
1.6
1.6.1
Equipment and Execution

Exploratory Drilling and Grouting
Percussion drilling equipment shall be used for drilling of exploratory drillholes,

grouting holes, control holes, sounding holes, and drainage holes etc. in rock and concrete both
above- and underground, if not otherwise requested by Gener.
Percussion drilling equipment shall be capable of drilling holes up to 50 m length
in any direction. Percussion drilling equipment shall be available from start of excavation work.
Bits with a minimum diameter of 45 mm shall be used for drilling.
Core drilling equipment shall be available as specified in Chapter 4 Investigation
and Instrumentation during construction.
Equipment units for excavation and rock support work may be used when
satisfying the above requirements.
600-TU-ETG-001
4
Water flushing shall be used during drilling of all grout holes. The use of grease
or lubricants on drill rods or use of mud for drilling is not permitted.
After drilling, the hole shall be flushed with water and air. Pumps for supply of air
and water for flushing shall be capable of delivering a pressure of minimum 10 bar.
The tolerance for collaring of drill holes is 0.10 m measured from theoretical
pattern and for alignment deviation the tolerance is 4% of the depth of the hole.
All drillholes shall be grouted with non shrink mortar unless otherwise ordered by
Gener.
Drillholes for grouting in soil shall be of the rotary type with casing, minimum
diameter 76 mm.
1.6.2
Holes for other Purposes

The purpose of drilling is indicated under the payment items in the Payment
Schedules.
The method of drilling is the choice of the Contractor. The diameter of the hole is
the choice of the Contractor, if not specified. The Contractor shall be able to drill long holes in
all directions and within the drilling accuracy specified. Steering rods and special bits may be
required in order to fulfil these requirements. Efficient equipment is required in order to secure
an adequate advance according to the time schedule.
The drillholes shall be equipped with permanent casing down to minimum 5 m
into unweathered rock. The casing shall be supplied with threaded end and transition reducer
for connection of specified size water pipes and valves. Casing and transition reducer shall be
hot dip galvanised. The inner diameter of the casing shall be equal to any specified hole
diameter. The transition between casing and rock shall be watertight in order to avoid that water
close to the surface or tunnel contour may leak into the drill hole. After drilling, the hole shall be
flushed with water and air. Pumps for supply of air and water shall be capable of delivering a
pressure of minimum 10 bar. The Contractor shall prepare a procedure for sealing and cleaning
of drill holes. The procedure shall be approved by Gener prior to commencement of Work.
Packers for water pressure testing and grouting shall be available for all drill hole
diameters.
All relevant field observations and measurements shall be logged.
Ground water monitoring shall be performed.
recorded twice a shift for each hole during drilling operation.
Ground water levels shall be
600-TU-ETG-001
5
1.6.3
Drilling Accuracy:
Collaring = 0.10m
Maximum deviation = 4% of drilled length
No drill hole shall come closer than 15m to tunnels and caverns if not otherwise
specified or instructed by Gener. If deviation measurements indicate that the hole is closer than
15m to tunnels and caverns, the hole shall be filled with expanding mortar and replaced with
new holes at the expense of the Contractor.
1.6.4
Deviation Measurements of Drill-holes

See Chapter 4, Investigation and Instrumentation during construction.
1.6.5
Water Pressure Tests
The Contractor shall keep adequate stock of all types and dimensions of packers
considered necessary from start of underground excavation work. The packers shall be of
proven types, designed for expansion either mechanically or by other approved means (e.g.
hydraulically). Packer function shall be verified by testing in steel pipe at surface prior to use in
boreholes. Pneumatic packers will not be accepted.
After expansion, packers shall provide an impermeable seal for pressurised water
and - if required - later grouting in any position with pressure as defined for grouting equipment.
Packers shall be equipped with a valve to allow sealing of the hole at the end of the grouting
process.
Single packers shall be used for testing in stages during drilling. Double packers
shall be used for testing after completion of drilling. Double packer separation shall be adjusted
to local rock mass conditions.
Pressure gauges and pumps for water pressure tests shall conform to specified
requirements given in Chapter 4, Investigation and Instrumentation during Construction.
1.6.6
Flushing between holes
If flushing between holes is required, the Contractor shall have available a high
capacity water pump (min 200 l/min.at 50 bar), air compressor and other equipment (radial
flushing head) needed for efficient flushing operation.
600-TU-ETG-001
6
1.6.7
Grouting
Equipment both for cement grouting and chemical grouting shall be available and
in working order at any time at the site.
Each unit of equipment for cement grouting shall include, but are not limited to:
Grout mixer
Grout agitator
Grout pump
Flow meter, pressure gauges for air, water and grout supply lines, grout supply,
valves, packers and fittings to supply a continuous flow of grout and an accurate pressure
control
The Grout Mixer shall be a high-speed colloidal grout mixer. The mixer shall be
capable of mixing grouts with water/ cement ratios between 0.4 and 10. An accurate
measurement of materials shall take place at the mixer so that mix proportions can be exactly
controlled. Cement may be added to the mixer by weight or by volume. Each component
added to the mixer shall be measured to an accuracy of +/- 5 %. Minimum mixer capacity shall
be 250 l.
The Grout Agitator shall be capable of keeping grout of specified water-cement
ratios (between 0.4 and 10) in suspension. It shall be equipped with screen to remove particles
not passing a 4.75 mm sieve. The sump shall be graduated to metric standards so that the
volume of grout injected into a hole can be measured accurately. The capacity of the agitator
shall not be less than twice that of the mixer.
The grout pumps shall be a progressive cavity, pulse free type, capable of
handling thin and viscous grouts with no pulse. The capacity shall be at least 0.08 m3 grout per
minute at a discharge pressure of 50 bar, and minimum 0.05 m3 per minute at 100 bar. The
pump shall be equipped with a pressure regulating device securing a maximum grouting
pressure within 10 % of the required pressure. The grout pumps shall be able to operate with
working pressure of at least 120 bar. Pressure gauges shall be Bourdon type or similar of heavy
duty quality and shall measure pressures as appropriate to the range of grouting pressure
employed. Two pressure gauges shall be supplied for the grouting plant, one at the header and
one at the pump. In addition a pressure recording unit shall be connected to the pressure line
from the grout pump. The dial size of the pressure gauge shall not be less than 150 mm. The
pressure recording unit shall record the pressure within 1 bar. The records may be in analogue
or digital form and with the possibility of pressure readings every minute. The Contractor shall
supply a calibrated master gauge for each pressure range for checking the accuracy of all
gauges used.
600-TU-ETG-001
7
The pump and the connected agitator shall be located at a distance of maximum
30 metres from any hole being grouted.
Packer dimension and construction of the packer shall correspond to the diameter
of the drill hole, to the drilling method used to produce the hole, and to the applied pressure.
Double packers and single packers shall be available. Disposable packers may be used if
approved by Gener.
For chemical grouting, suitable pumps as well as necessary accessories shall be
available. Required working maximum pumping pressure is 250 bar. Equipment shall be
compatible with grout data as given by manufacturer. Pumping capacity shall as a minimum be
4 l/min.
All grouting units shall at all times be clean and in proper working condition. The
Contractor shall supply sufficient operating personnel, supervision, labour, spare parts and tools
to operate the units at full capacity and top efficiency. A minimum of three grouting units of each
type shall be available at site.
The grouting plant shall be provided with satisfactory storage for supplies of
grouting material so that the operations may proceed without interruptions. The plant shall be
provided with suitable housing for protection against rain and direct sunshine.
Flexible grouting tubes, both for chemical and for cement grouting, will be
required for contact grouting, and shall be installed as required by Gener. Acceptable brands
are FUKO 2 for cement grouting and Multiject (ULTRA) or FUKO 1 for chemical grouting, or
equivalents. All feeder tubes, couplings and valves shall be certified for working pressure up to
120 bar.
1.7
Logging of drill holes

All drill holes shall be logged. The log shall include the following as a
minimum.
Precise location, direction and length of each hole.
Location of weakness zones, including notes on variation in penetration rate
and colour of returned flushing water. Location shall be recorded if loss of
flushing water occurs.
Location, nature and quantity of any occurrence seepage.
Results from pressure testing shall be presented graphically.
For core drilling, the log shall in addition include information as specified in
Chapter 4.
600-TU-ETG-001
8
1.8
Water Pressure Testing
Water pressure testing shall be performed to determine hydraulic conductivity of

surrounding rock mass and the need for grouting. Water pressure testing shall be carried out in
boreholes as directed by Gener, and with pressures as specified.
Prior to testing, the boreholes shall be flushed with water if necessary in
combination with air, for cleaning of the hole, and the equipment shall be calibrated according to
specifications listed in Chapter 4 Investigation and Instrumentation during construction.
Groundwater level shall be measured prior to testing.
Water pressure tests shall be recorded in Lugeon units, and 1 Lugeon is defined
as a loss of water of 1 litre per minute per metre of borehole under test at an overpressure of 10
bar. If the length of the borehole under test exceeds 5 m, the length of the borehole shall be
taken as 5 m for the purpose of calculating the Lugeon value. For applied overpressures other
than 10 bar the Lugeon value shall be assumed to be linearly proportional to the test pressure.
The water pressure tests shall be performed with double packers and/or single
packers as directed by Gener. Packers shall be pressurised mechanically or hydraulically with
liquids, not inflated pneumatically. The water pressure test shall normally start with the upper
packer located at the top of the hole, and then with setting of packers at 5 m depth intervals.
For each test, the water pressure shall be maintained in periods of 5 minutes with recording of
water loss until 2 consecutive measurements of the loss are equal.
In cases where the tests indicate open or partly open connecting channels
between two or more boreholes, flushing with water or a combination of water and air may be
required to clean out infill material prior to grouting. For such flushing the Contractor shall have
available a high capacity water pump.
1.9
Grouting
1.9.1
Grouting Materials
1.9.1.1
Water
Water quality shall be as specified for concrete.

1.9.1.2
Cement
The cements to be used shall be fresh Portland Cements. Transport, handling

and storage shall conform to the requirements in the corresponding clauses of the specifications
for cement to be used in concrete or as recommended by the manufacturer.
The cement grout shall be of the stable mix type.
600-TU-ETG-001
9
The following cement grout types may be used:
Grout type A:
Portland Cement conforming to ASTM C150 and having a specific surface of not
less then 400 m2/kg (Blaine Value) with not more than 1% by weight being
retained on a sieve 200 and with stabilising and plasticising admixtures of micro
silica (Elkem Materials-MultiGrout GroutAid or equivalent) and superplasticisers
(Sika-SP 40 or equivalent). The maximum bleeding value shall conform to the
recommendations of ISRM Commission on Rock Grouting, which state that the
grout suspension (with all additives) is considered stable when the sedimentation
rate H/H after 2 hours remains under 5%.
Water cement ratio: Typically 0.45 - 1.2. Marsh funnel viscosity: 36-50 sec.
Grout type B:
The cement to be used shall be micro fine Portland cements with a specific
surface of not less than 650 m2/kg (Blaine Value), with not more than 1% by
weight being retained on sieve 30. The maximum bleeding value shall conform to
the recommendations of ISRM Commission on Rock Grouting, which state that
the grout suspension (with all additives) is considered stable when the
sedimentation rate H/H after 2 hours remains below 5%.
Water cement ratio: Typical 0.45 - 1.2. Marsh funnel viscosity: 36 - 50 sec.
Grout type C:
A quick setting, fine grained grout with a pot life that can be regulated in a
controlled manner between 10 minutes and 1 hour for a mix in proportion 1:1,
water/cement (weight) at 25o C. Type: Accelerator aided mix designs or
premixed blocker agents as Thermax + C-Max (Elkem Materials-MultiGrout) or
equivalent.
1.9.1.3
Admixtures
Gener may require the addition of materials other than those specified above in
order to improve the properties of cement grouts with respect to stability, pumpability,
acceleration and retarding, and penetration ability. Such admixtures shall include, but are not
limited to, micro-silica powder, as well as expanding, water reducing, accelerating and stabilising
admixtures.
600-TU-ETG-001
10
1.9.1.4
Chemical grouts
Chemical grouts are required for special purposes.

The following chemical grouts may be used:
Grout type D:
Polyurethane grout - TACSS 020 (De Neef) or similar.
Grout type E:
Epoxy grout with extended potlife - Mapepoxy BI-R (Rescon Mapei) or similar.
Alternative products with documented equivalent properties will be accepted and
may be offered by the Contractor as an alternative.
Transport and storage of chemical grouts shall be as specified by the

manufacturer.
1.9.2
Cement Grouting above ground

Grouting shall be done according to procedures and criteria approved by Gener.
The procedure for cement grouting starts with drilling of grout holes. Before
grouting, the hole shall be flushed for 3 minutes or until return water is clean. If the flushing
reveals washing out of material into neighbouring holes, a more comprehensive flushing has to
be done.
Control holes will be drilled between grouted holes when the grout agents have
set, and the grouting will continue in a split spacing system until control holes demonstrate that
the required permeability is reached unless otherwise ordered by Gener.
It will be assumed that the required permeability is reached when the gross grout
take in the control hole is below the limit defined by Gener.
Packer intervals will be 3 - 5 m for the above ground grouting works.
Grouting of soil shall be performed placing the packer in the casing. The grouting
shall be performed in stages of 2-3 m. When the casing is withdrawn, full grouting pressure
shall be applied.
If grout is pressed from one hole into neighbouring holes, all holes shall be
grouted simultaneously according to the procedure described above.
600-TU-ETG-001
11
The Contractor shall be able to hook up to such holes for simultaneous grouting
of up to 5 holes.
The grouting sequence shall start with the leanest grout mix at each packer
setting. If the grout take exceeds a certain quantity of cement (will be specified during
construction) without increasing grout pressure, a richer grout mix or other grout types shall
follow. Grouting of one stage shall not be approved as completed until it has been set under the
specified pressure for at least 5 minutes or the stop criterion defined by Gener as maximum
grout take per meter drill hole is reached.
Grout type C shall be used for the termination of all holes if not otherwise ordered
by Gener.
If grout is found to by-pass to rock surface during grouting, such leaks shall be
plugged or caulked. Plugging materials and spill of grout shall be removed as required by
Gener.
The Contractor shall in his Tender specify the manufacturer and type of grout he
intends to use.
1.9.3
Cement Grouting underground

Grouting shall be done according to procedures and criteria approved by Gener.
The procedure for cement grouting starts with drilling of grout holes. Before
grouting, the hole shall be flushed for 3 minutes or until return water is clean. If the flushing
reveals washing out of material into neighbouring holes, a more comprehensive flushing has to
be done.
All holes drilled shall be grouted. No water pressure tests shall be carried out.
Control holes will be drilled between grouted holes when the grout agents have
set, and the leakage from these holes will govern further grouting and control procedure, unless
otherwise ordered by Gener.
Packer intervals will be as directed by Gener.
Normally, cement grouting underground is to be performed at high pressure with
a cement suspension consisting of cement, water and admixtures as specified. The detailed
procedure will be defined during the construction phase according to the local rock mass
conditions.
If grout is pressed from one hole into neighbouring holes, all holes shall be
grouted simultaneously according to the procedure described above.
600-TU-ETG-001
12
The Contractor shall be able to hook up to such holes for simultaneous grouting
of up to 5 holes.
The grouting sequence shall start with the leanest grout mix at each packer
setting. If the grout take exceeds a certain quantity of cement (will be specified during
construction) without increasing grout pressure, a richer grout mix or other grout types shall
follow.
Grouting is terminated when a predefined pressure level or grout take level has
been reached. Grout type C shall be used for the termination of all holes if not otherwise
ordered by Gener.
If grout is found to by-pass to rock surface during grouting, such leaks shall be
plugged or caulked. Plugging materials and spill of grout shall be removed as required by
Gener.
The grout material shall be adequately set (cured) prior to blasting into a grouted
area. The required setting-time prior to commencement of drilling and blasting at the face
depends on the result of the grouting. It is a requirement that the setting-time shall be adjusted
to the time needed for preparation for the next blast. Maximum normal setting time is 1 hour.
Gener shall immediately be notified if longer setting-time is required.
The Contractor shall in his Tender specify the manufacturer and type of grout he
intends to use.
1.9.4
Chemical Grouts
In principle, the procedures are similar as for cement grouting.
Chemical grout may be required in contacts between concrete/rock,

steel/concrete, steel/rock and in rock where especially low permeability is required.
The Contractor shall in his Tender specify the type of grout he intends to use for
Grout Type D and E.
1.9.5
Filling of Cavities with Concrete or Mortar (Consolidation grouting)
In cases where the exploratory drilling or testing locates open channels or cavities
between concrete and rock, it may be required to fill or plug such cavities by pumping in
concrete or mortars through one or more boreholes or preinstalled tubes.
Infilling of sand, gravel or crushed rock prior to grouting or concreting may also be
required in order to achieve blocking of potential leakage channels.
600-TU-ETG-001
13
The Contractor is required to have equipment available at site for performance of
such works.
2.
ROCK EXCAVATION
2.1
Scope and definitions

2.1.1
Coverage
This Chapter specifies requirements for all underground and aboveground rock
excavation works. Any excavation method that would fulfil the specified requirements may be
used, i.e. drill and blast method and other mechanical excavation methods.
The Contractor shall provide all material, labour and equipment and carry out all
works, temporary works and tests required for completion of excavation.
The Contractor shall assume full and sole responsibility for safe working
conditions in all excavations, and the health and safety of all workers and visitors to the
worksite. See also definition in Chapter 3 Rock Support. In addition to any special provisions
for safety included in these specifications, all of Contractors operations shall conform to all
applicable laws and regulations.
2.1.2
2.1.2.1

General
Rock is defined as all materials, which require blasting, or the use of TBM or
RBM, or the use of mechanical breakers for their removal, and which cannot be extracted by a
thirty tons excavator with backhoe with teeth, or equivalent equipment.
Boulders larger than 1 m3 shall be classified as rock. Boulders less than this
shall be classified as soil.
All types of materials found in rock formations underground shall be classified
according to the rock mass quality classification listed below.
Gener shall decide if the material shall be classified and measured as rocks, and
his decision shall be final.
600-TU-ETG-001
14
2.1.2.2
Rock Mass Quality Classification
During excavation of rock, a rock mass quality classification will be performed by

Gener after each blast. To facilitate the work the rock mass quality will be grouped into five
classes, as defined.
q1 Very Good
Massive to low joint frequency, Jv < 5/m3. Tight joints, unaltered strong rock and
insignificant stress slabbing.
q2 Good
Low to moderate joint frequency, 5< Jv < 10. Strong rock with none or
insignificant alteration and with coating on some joints. Low to moderate stress
slabbing.
q3 Fair
Moderate to high joint frequency, 10< Jv < 20. Moderately strong to strong rock
generally with coated joints and with some seams and some minor weakness
zones. The rock mass may be slightly weathered. Also applies to q1 and q2
class with moderate to high intensity stress slabbing; and to medium to low
strength rock subjected to low to medium stresses causing plastic deformations.
q4 Poor
High joint frequency, Jv > 20, clay seams (fault zones, swelling clays) in
moderately strong rock. Also applies to moderately weathered strong rock and to
high to very high intensity stress slabbing in q1 and q2 class rock mass; and to
medium to low strength rock subjected to medium to high stresses causing plastic
deformation.
q5 Extremely Poor
Completely crushed rock containing a significant amount of secondary clay
minerals as in major fault zones. Smectite clays may lead to significant swelling
and squeezing. Also applies to highly weathered rock and to low strength rock
mass subjected to high stresses causing plastic deformation.
2.2
Submittals by the Contractor

2.2.1
General
Submittals that the Contractor is required to make to Gener are described below.
documents:
600-TU-ETG-001
15
2.2.2
Documents for submittal-Rock excavation

2-1.
Documents for submittal Rock excavation
Issue for
Issue for
Documentation
approval
info.
Organisation plan for the rock excavation work showing
*
the responsibilities and the qualifications of the personnel.
Table 2-1:
Data sheets for explosives and detonators.

Drawings showing need and location of construction
niches.
Method of ventilation, control and monitoring system
including data sheet for equipment and calculation of
ventilation and energy requirements.
Excavation procedure for each area, including intended
rock excavation, removal and deposit method, time
schedule and sequence for excavation, rock support and
monitoring.
Description of blasting procedure, including position and
depth of holes, types of explosives, size of charges, timing
and firing sequences.
Procedures for geometric control.
Weekly progress report for excavation, showing planned
progress versus actual progress (cut off Sunday at 2400
hours).
Monthly documentation of correct setting out of the
excavation contours (cut off last Sunday each month at
2400 hours).
Issue time
6F
6F
6F
6F
6F
6F
*
6F
1T
1T
2.2.3
Test Reports
The Contractor shall perform tests and prepare and submit test reports in
600-TU-ETG-001
16
Table 2-2:
Item
Perimeter blasting test report
Documents for submittal Blasting tests

Issue for
Issue for
approval
info
*
Blast vibration test report

2.2.4
Issue time
1T
1T
Documents for submittal-TBM excavation

2-3.
Table 2-3:
Item
Documents for submittal TBM excavation

Issue for
Issue for
approval
info
TBM specifications, cutter head and back up system,

complete
Issue time
6F
List of major spareparts, at site, workshop and

manufacturer
6F
Description and data sheets for mucking system
6F
Description and data sheets for secondary transport

system in tunnel (personnel, equipment and materials)
6F
Working procedure for each area, including intended

rock excavation, time schedule and sequence for
excavation, rock support and monitoring
6F
Description and data sheets for exploratory and grouting

drilling ahead of face
6F
Description and data sheets for grouting equipment and

method
6F
Description and data sheets for rock drills and bolting at

cutter head and behind
6F
Description and data sheets for application of sprayed

concrete between cutter head and back up.
6F
6F
6F
6F
6F
Description and data sheet for installation of circular

steel sets and wire mesh at cutter head, including the
erector
Procedures for material and equipment supply to tunnel
front, including for excavation, rock support and grouting
works
Organisation plan for the TBM rock excavation work
showing the responsibilities and the qualifications of the
personnel
Description and data sheets for Monitoring and Logging
system for TBM operational data
600-TU-ETG-001
17
Reporting procedures
Routine reports
6F
*
1T
2.3
Rock Excavation
2.3.1
General Requirements
Prior to commencement of the work, the Contractor shall submit to Gener a plan
showing manpower and equipment for excavation and support work intended to be used, spare
parts and supplies on the Site, and the expected advance rate of excavation and tunnelling
including time for support work. Only experienced supervisors, foremen and well-trained
tunnelling crews shall be employed for the work.
The Contractor shall be responsible for the management and sorting of all
excavated materials to enable the placement and disposal of materials in accordance with the
Contract. Excavated materials shall, according to their nature and to the Contractor's materials
management plan, be placed as fills in their final locations in the Works, stockpiled for later
placement, used for aggregate production, or removed to a nominated or approved spoil
disposal area. All excavated materials belong to Gener and no material shall be removed from
the Site without the written approval of Gener.
Excavation in rock shall achieve stable, reasonably regular rock slopes and
surfaces with as little overbreak as possible. Excavation of the underground caverns shall be
done in stages. The bench height above- and under-ground shall not exceed heights giving full
access for rock-strengthening works in the walls of each bench.
The Contractor may choose his own methods for drilling, blasting and
transporting the rock. Except where otherwise specified, perimeter blasting shall form the final
surfaces in underground openings. Charging of drill holes as well as type of ignition, drilling
patterns etc., shall be according to modern methods and recognised good practice.
The Contractor shall observe and carry out all excavation work according to rules
and regulations regarding the import, transport, storage and use of explosives issued by and
public authority having jurisdiction in respect of the same. Detailed records shall be kept by the
Contractor and submitted daily to Gener giving the types and quantities of explosives used,
delivered and in stock. Transport of explosives and detonators shall be in vehicles suitably
equipped for this purpose.
600-TU-ETG-001
18
The Contractor shall not later than 6 weeks ahead of start of blasting works,
provide Gener with a list of blasting licence holders. Only qualified persons shall be permitted to
conduct blasting operations.
Where firing is carried out electrically the Contractor shall take all precautions
necessary to prevent premature explosions. During thunderstorms and other electrical
disturbances charging and firing is not permitted and warning shall be given to all operators
when charging is in progress.
An instrument measuring static electricity levels shall be installed at each tunnel
portal. The instrument shall be connected to an easily visible warning device.
All metal mains, ducts and tracts shall be properly earthed at the entrance to the
underground working.
Gener may require use of non- electric ignition systems without additional
compensation to the Contractor.
The times at which blasting may be carried out are to be subject to the approval
of Gener and shall be decided so that the blasting does not unreasonably disturb the population
or other works.
After excavation of soil material, the rock surface shall be sufficiently cleaned for
drilling and placing of explosives to the satisfaction of Gener. The cleaning shall be done to at
least 1.5 m outside theoretical rock contour lines or 1.0 m outside actual contour lines.
The design theoretical rock contour lines and levels of excavations are defined as
those shown on the Drawings or specified in the Contract, or as adjusted at site or otherwise
determined by Gener.
Excavations shall follow the theoretical rock contour lines and levels or such other
limits as the Contractor may require to enable him to construct the Works in accordance with the
Contract considering collaring accuracy and hole deviation specified. Excavation beyond the
theoretical rock contour lines and levels made without Gener's direction or approval, including
but not limited to, excavation to provide working space and excavation below approved stripping
levels, shall be backfilled with concrete at the Contractors expense unless otherwise specified or
approved.
The Contractor shall be solely responsible for all damage or accidents resulting
from blasting of temporary, permanent or subsidiary works, or to the property of Gener or of
others, as well as for injury to persons.
The Contractor is responsible for covering and required protection in connection
with blasting. Debris from blasting and spill from transportation are not allowed outside the
600-TU-ETG-001
19
excavation area. The Contractor has to clean up such material as Gener finds it necessary.
The Contractor shall regularly inspect the excavated fronts of all works under his jurisdiction,
including temporary and permanent access roads and shall forthwith remove and dispose of any
material, which Gener and/or the Contractor deem loose or unsafe.
Blasting in the vicinity of completed, or partially completed, concrete structures
shall be subject to Geners consent. Normally, blasting shall not take place in the vicinity of
newly concreted structures until 10 days after concreting. The restriction does not apply to
blasting close to installed rock support in underground openings.
Limits for blasting induced vibrations from repeated events are defined as peak
particle velocities (mm/sec) measured at the structure. The limit is valid for both horizontal and
vertical peak particle velocities and is given in Table 2-4. For single events Gener will establish
less stringent limits in each case.
Table 2-4:
Limits for peak particle velocity
Type of construction
Peak particle velocity
Ordinary buildings founded on soil
20 mm/sec
Ordinary buildings founded on rock
50 mm/sec
Massive concrete structures founded on rock
70 mm/sec
100 mm/sec, or as determined by
Adjacent permanent underground openings
Gener
Tanks, pipes and valves. Measured on foundation to rock 40 mm/sec
Tanks, pipes and valves. Measured on foundation on soil 20 mm/sec
Transformers and other sensitive equipment in operation.
12 mm/sec
Measured on foundation.
Transformers and other sensitive equipment not in
40 mm/sec
operation. Measured on foundation.
Gener may adjust limits according to characteristic frequencies obtained and
experience gained during execution.
The Contractor shall monitor blasting operations as well as magnitude and
intensity of ground vibrations when required. The Contractor is responsible for keeping the peak
particle velocity below given limits and to document this by vibration recording instruments
available at the site. The vibration recorder shall have minimum 3 channels and be able to
record peak particle velocities in the range 1 - 250 mm/sec with an accuracy of 1 mm/sec. The
instruments shall give linear recordings in the frequency area 5 to 300 Hz. Geophones for
horizontal and vertical PPV measurements shall be available. The records shall be submitted
weekly. The Contractor shall provide a yearly certificate from the manufacturer or approved
authority verifying the accuracy of the vibration monitoring apparatus.
600-TU-ETG-001
20
Before commencing the rock excavation work, the Contractor shall work out and
present a quality assurance plan that ensures that the rock excavation work is performed
according to the Contract requirements.
The rock surface shall be inspected after each blast, and action for immediate
securing at the face shall be taken as required. Gener shall have access to the face in order to
carry out mapping of the rock conditions revealed. In cases of adverse rock conditions or
significant deterioration of the conditions Gener shall be notified immediately.
2.3.2
Ventilation
The ventilation system shall be efficient and reliable during the excavation period
in order to provide a safe and comfortable working environment inside tunnels and caverns.
Toxic gases shall not exceed levels according to local requirements or as shown
in Table 2-5 whichever is strictest, at any time when people are in the tunnels:
Table 2-5:
Limits for toxic gas levels
CO
35 ppm
CO2
5000 ppm
SO2
2 ppm
NO2
2 ppm
NO
25 ppm
Air velocity shall always be higher than 0.3 m/s in the cross sectional area of
tunnels and caverns. The air breathed by persons shall contain not less than 19% of oxygen by
volume.
The environment inside the tunnel will be governed by seasonal variations in
temperature, humidity, rock temperature and by work activities ongoing within the tunnel.
The maximum wet bulb temperature inside the tunnel shall not exceed +28C.
The fans shall be robust and efficient. Each fan shall be capable of providing
variable airflow to suit the construction sequence and activity level inside each tunnel as work
progresses. Each fan shall be supplied complete with all necessary components for
commissioning and use.
Noise emission of each fan shall not exceed 75 dB (A) measured at 45 to the
axis of the fan at a distance for 10 m from the inlet.
600-TU-ETG-001
21
All components of the duct system shall be non-flammable.
The ducting shall be of a safe robust material. Flexible ducting shall have a high
tear resistance and shall be appropriately reinforced and maintained.
The ducting system shall be resistant to the tunnel environment and shall not
deteriorate as a result of inter alia:
Condensation
Diesel and nitrous gases
UV light
Weak dilutions of acid
If the Contractor expects the conventional ventilation system to be insufficient for
keeping the wet bulb temperature below 28C, a separate cooling system shall be installed. The
condenser shall be water-cooled.
A control and monitoring system for optimisation shall be provided.
The Contractor shall describe the details of the system that will be used.
The parties to the contract shall produce a schedule of gases and pollutants to be
tested for, including both the frequency and the methods of testing. The recommendations of
BS 6164 Section 4 shall be followed, but this shall not restrict the range of testing to be carried
out in any particular location.
2.3.3
Illumination, Communication and Roadways
The Contractor shall install and maintain illumination as required for safe and
efficient working conditions and inspection of the work executed.
The Contractor shall install and maintain a system of telecommunication at all
work fronts.
The Contractor shall maintain all temporary and permanent roadways in good and
dry conditions to facilitate efficient and quick transportation aboveground as well as
under-ground.
2.3.4
Survey
All surveying shall be carried out as specified for Surveying work.
600-TU-ETG-001
22
2.4
Open Cut Excavation
Excavation beyond the theoretical rock contour shall wherever possible be

backfilled with approved concrete, unless otherwise directed by Gener.
The slopes of permanent batters are assumed to be vertical unless other slopes
are given on the Drawings or directed by Gener.
During the progress of the work Gener may examine and investigate the ground
revealed in the excavations and may carry out investigations of groundwater levels, soil and
rock properties in the ground adjacent to the excavations. Such investigations may require
alterations to the limits of the excavations for such purposes as to provide sound foundations or
stable batters.
In the Bill of Quantities rock excavation is divided into the following categories:
Bulk rock excavation and

Trench/ditch rock excavation with bottom width less than 2.0 m.
2.5
Underground Excavation
Underground excavation comprises excavation of all tunnels, shafts, caverns and

other underground openings shown on Drawings. Any recesses, trenches, enlargements etc.
required by the Contractor will not be measured for payment.
The excavation procedure shall always be adapted to the local rock mass
conditions. When traversing weakness zones or other areas of heavily jointed or otherwise
incompetent rock, pilot tunnelling, dividing of the section, and/or advancing with shorter pull than
normal may become necessary. Spiling, immediate application of sprayed concrete, reinforced
sprayed concrete lining, pressure grouting or other support measures, further described in
Chapter 1 and Chapter 3, may also be required. The methods to be used for excavation and
support shall be subject to Gener's approval.
In all waterways a rigid template of the same shape and dimensions as the
theoretical cross-section shall pass through. The direction along which the template moves
shall nowhere be more than 7 off the theoretical alignment.
Any subsequent slashing, wedging or re-drilling of rock that may be necessary in
order to meet the above requirements is the responsibility and cost of the Contractor.
Control of compliance with the design requirements shall be carried out by the
Contractor at regular intervals as directed by Gener.
600-TU-ETG-001
23
2.6
Drilling and Blasting (Above- and Underground)

2.6.1
General
Prior to excavating rock at a given location the Contractor shall, after notifying
Gener, carry out a survey of the surface of the rock as agreed by Gener (See also specifications
for Surveying work).
Before commencing any drilling and blasting the Contractor shall submit for
Gener's approval the drilling-, charging- and ignition patterns he proposes to use. Such
approval shall, however, not exempt the Contractor of the full liability of any blasting operations.
The drilling equipment shall include a device for measuring the direction of
drilling.
In order to minimise overbreak and requirements for rock support, perimeter
blasting (soft blasting smooth contour blasting technique) shall be used on all final rock
surfaces.
The length and size of blast rounds shall be regulated according to the prevailing
rock conditions. When deemed necessary from stability considerations, Gener can order
reduced round lengths and/or subdivision of the cross section.
When deemed necessary from stability considerations, Gener can order change
in excavation shape, both the arch height and the symmetry, within the given crosssectional area.
Design drawings show the theoretical rock contour. Special rock mass conditions
could require cross-section adjustments which shall be decided and/or approved by Gener.
2.6.2
Excavation Tolerances
The excavated area shall at no point be less than the theoretical area for each
section given on the Drawings. Rock protrusions inside theoretical contour lines are not
accepted.
If the Contractor considers it necessary to request for excavation outside
theoretical contour to obtain access for temporary works or installations, such request shall be
forwarded to Gener and the work shall be at the Contractor cost and time.
600-TU-ETG-001
24
2.6.3
Drilling Accuracy
The general requirements for drilling accuracy are as shown in Table 2-6.
Table 2-6:
Drilling accuracy
Excavation
Drill holes/row
Collaring
Alignment
Aboveground
Contour holes
100 mm
2% of depth of hole
Aboveground
Next rows
200 mm
2% of depth of hole
Underground
Contour holes
100 mm
4% of depth of hole
Underground
Next rows
200 mm
6% of depth of hole
Shafts
Pilot holes and reamed shaft 100mm
1.5% of depth of shaft
TBM tunnels/shafts
Tunnel centerline
+/- 50mm in all directions
2.6.4
NA
Perimeter Blasting
2.6.4.1
General
Perimeter blasting shall be applied on contours in order to ensure smooth final

surfaces, minimise overbreak and reduce the subsequent support measures. Smooth blasting
or pre-splitting may be applied.
This includes drilling of contour holes c/c 700 mm with max. diameter 51 mm
and use of special low strength explosives. The row next to contour holes may also require
charge limitations.
As a general rule the distance between the perimeter and the nearest row of
holes of the main round shall be 1.3 times the spacing of perimeter holes for smooth blasting.
For pre-splitting this distance shall be 0.5 times the burden in the main round, or smaller than
the average joint spacing.
The selection of these and other pertinent parameters shall be based on
experience gained from the initial rounds, and shall be subject to the approval of Gener.
2.6.4.2
Smooth Blasting
The result of smooth blasting is governed by the following parameters:

diameter of contour holes,
spacing of contour holes,
distance between the row of contour holes and next row of holes (burden),
type and size of charges used,
ignition pattern.
600-TU-ETG-001
25
This method is based on closely spaced contour holes, with reduced charges to
be fired as a final clean-blast after the main round on the last number of delays. The method
shall prevent extensive fracturing of the rock mass beyond the contour.
2.6.4.3
Pre-splitting
The principle of pre-splitting differs from that of smooth blasting mainly by its
ignition pattern. The contour holes are blasted prior to the main round, and the crack formed
should act as a barrier which will tend to limit further fracturing of the rock mass beyond the
contour from the vibrations of the main round.
2.7
Drilling and Reaming of Shafts by raise-boring machine (RBM)

The Contractor selects the type of the raise-boring equipment he intends to apply.
The proposed working methods for the various tunnel sections and shafts shall be
described in detail by the Contractor and submitted with the Tender. The Contractor shall
submit a description with his Tender of details on the RBM and of the ancillary equipment to be
provided, with particular emphasis of the items listed below.
A high degree of drilling accuracy is required and defined according to Table 2-6.
Registration of rock mass quality shall be performed concurrent with drilling of the
pilot holes. Any abnormalities shall be reported immediately to Gener and the requirement for
stabilisation grouting by high pressure shall be evaluated concurrent with the drilling.
Pilot holes shall be grouted and re-drilled if required.
Where shaft excavation or raise boring operations intersect proposed or
completed tunnel alignments, the Contractor shall prepare a detailed work plan (including
temporary works as necessary) to indicate and assure the proper coordination and avoidance of
interferences between tunnelling and shaft construction. This is also required for rock support
works to be performed in the shafts.
2.8
Tunnel excavation by tunnel boring machine (TBM)

2.8.1
General
For the sake of clarity, the following terms shall be used in connection with the
Work as defined herein:
a)
Excavation by TBM: Continuous excavation of tunnels by means of a

full-face boring machine (TBM).
b)
600-TU-ETG-001
26
Excavation by raise boring: Continuous excavation of shafts by means of a
raise-boring machine (RBM).
c)
Excavation by drilling and blasting:

applying drilling and blasting (D&B).
Excavation of tunnels and shafts
d)
Heading face: The advance end of a tunnel or other excavation at which the
work is progressing.
e)
Machine zone: Refers to tunnels excavated by a TBM and is defined as the

space between the heading face and the outer end of the rear gripper
mechanism + 10 m rearwards.
f)
Backup equipment zone: Refers to tunnels excavated by TBM and is

defined as the space between the end of the machine zone and the end of
the TBM auxiliary equipment.
g)
Rear zone:
Refers to the entire tunnel or shaft section extending
respectively from the heading zone, or bottom range zone, or for TBM
excavation the backup equipment zone, to the portal.
h)
Stroke: The advance of the heading face in a TBM excavation from one regrip to the next grip.
General technical requirements and specifications related to tunnel excavation

are presented in Chapter 2 above and are valid also for TBM excavation.
The Contractor selects the type of TBM to be used, as specified in 2.8.2 below.
The proposed working methods and equipment for the various tunnel sections shall be
described in detail by the Contractor and submitted with the Tender, including description also of
the ancillary equipment to be provided, with particular emphasis of the items discussed below.
The TBM's shall be new, or refurbished for use on this Project, and shall be
assembled on completion of fabrication or refurbishment, before shipment, and tested to
demonstrate that all components operate correctly. Gener shall be permitted to witness testing
and to inspect TBM's at the premises of the manufacturer or refurbishing contractor at any stage
during fabrication or refurbishing. Such inspections or testing shall not release the Contractor
from any obligation as specified under the Contract.
The specified diameters are the minimum bore diameter to be allowed, after
maximum allowed wear of the edge cutters is reached.
2.8.2
Requirements to TBM machines
The Contractor selects the type of TBM machines to be used. The machines
must be capable of coping with the expected rock conditions, in particular with the expected
hard rock, mixed-face conditions and varying rock cover in a satisfactory manner and shall be
600-TU-ETG-001
27
equipped accordingly. The capability of the TBM machines includes but are not limited to the
following technical requirements:
The TBM's must be built for and equipped with back loading cutter system having
a minimum cutter diameter of 482,6 mm (19).
Minimum cutterhead power (torque) shall be 2200 kW for the Alfalfal II and
Volcan machine options, 3000kW for the optional Las Lajas machine.
The TBM machines shall be equipped with variable frequency drive system.
The TBM cutterhead shall be designed and constructed for allowing overcutting
when required, minimum 100mm around the tunnel periphery.
The bidder shall include in his offer one spare main bearing for each TBM
machine in stock at manufacturer workshop or at his own stock facilities.
An adequate stock of spare parts shall be maintained at the Project Area,
ensuring that interruptions for maintenance and repair will be kept to a minimum. A list of major
spare parts that will be available at the Project Area shall be submitted with the Tender.
The TBM machines shall be equipped with a monitoring and logging system for
TBM operation data. Machine operating parameter data shall be collected in real time, stored
and moved from the TBM to the surface by either manual methods or by a cabled modem
system. File structure shall be exportable to the user applications MS Excel and MS Access.
In addition to this, a simplified method for monitoring and logging of the operation
of the TBM shall be established by installing an Ampere reader and logger at the transformer
unit supplying the TBM. The reader and logger shall be connected to the site office of Gener, in
order to make him able to follow tunnel activities on a continuous basis.
Access to the heading face, also for Gener must be assured.
Should the excavation progress show that the selected TBM is inadequate or
unsuitable to complete the drive under the terms of the Contract, then the Contractor will be
obliged to proceed with D&B excavation under the same contractual obligations as with TBM
excavation. In such case the Contractor will have no right whatsoever to claim for any extension
of the time for completion of the Work.
600-TU-ETG-001
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2.8.3
Backup system
Backup system must be designed and constructed to permit the excavation of the
actual tunnel geometries, including capability to pass through areas where the 100mm
overcutting is performed by the cutterhead, or where reduced due to heavy rock support.
Solid protection roofs have to be installed over all workplaces, i.e. locations where
workers are stationed on a more or less continuous basis.
The Contractor shall detail and explain with his Tender the mucking system, of
sufficient capacity, he intends to use and, as applicable, the type of transport system he intends
to use including provisions for tunnel dewatering along the invert.
The accuracy of the advance shall be continuously assured by a laser beam and
a guidance monitoring and logging system with high accuracy in order to comply with the strict
tolerances for the tunnel alignment defined in Table 2-6.
2.8.4
Exploratory drilling, grouting and rock support
Technical requirements and specifications related to exploratory drilling, grouting

and rock support defined in Chapter 1 Drilling of holes, exploratory drilling and grouting and
Chapter 3 Rock support are valid for tunnel excavation with TBM, unless otherwise stated in this
Chapter 2.8.
TBM's have to be constructed so that proper and efficient installation of all rock
support elements (rockbolts, spiling bolts, sprayed concrete, circular steel sets, lattice girders,
wire mesh etc.) is possible both in the machine zone and in the backup equipment zone.
Depending on rock conditions, it will at times be necessary to place initial support
near the heading face, in front of the grippers. In this area it shall be accommodated for
minimum two drilling machines for drilling and installation of radial rock bolts, one machine on
each side of the main beam of theTBM. These drills shall be mounted on custom designed
fixtures which allows them to be used while the TBM is advancing, and to bore a near-radial
pattern of holes in the rock for the installation of dowels and rock bolts. Each drill shall have
capacity and technical specifications complying with Atlas Copco 1238 or equivalent equipment
and be operated completely independently of the other drill.
A circular steel set erector system shall be installed immediately behind the
cutterhead, and capacity shall be available to enable installation of steel sets in this area
whenever required. The steel set erector shall also allow for efficient installation of lattice
girders and wire mesh in the same area of the TBM.
The grippers of the TBM shall be equipped with recesses in order not to deform
the steel sets and lattice girders when passing by them.
600-TU-ETG-001
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Each TBM machine shall be equipped with minimum 2 drilling machines allowing
for drilling holes ahead of tunnel face for exploratory and grouting purposes, in addition to drilling
for spiling bolts, as specified in Chapter1 Exploratory Drilling and Grouting, and in Chapter 3
Rock support.
These probe drills shall allow for drilling of holes around nearly the entire 360
degree perimeter at a variable lookout angle of 10-30 degrees from the centre line of the tunnel,
and shall be subject to the approval of Gener.
Hole lengths shall be up to 50 meters for exploratory and grouting holes. These
drillholes can only be performed when TBM boring operation is stopped, and therefore the
drilling capacity must be the best possible, complying with capacities and specifications as
presented by Atlas Copco 1838 or equivalent. These drilling machines should also be capable
of drilling spiling bolts ahead and around the cutterhead, in umbrella pattern, and with lengths up
to 8 meters, also at a variable lookout angle of 10-30 degrees from the centre line of the tunnel.
Two complete grouting lines shall be installed and operated along the back up
system.
High capacity Robots for sprayed concrete application during boring process shall
be located in the machine zone. Collector buckets for rebound material shall be allowed for.
Double lances running on rings or equivalent high capacity equipment shall be provided, being
supplied by twin sprayed concrete pumps, installed along the back up and at considerable
distance away.
2.8.5
Invert concrete segments
Invert concrete segments shall be supplied and installed in the machine zone
during excavation of all TBM tunnels. The segment design and installation shall allow for proper
and efficient placing of steel sets and lattice girders in the same area. The tunnel invert shall be
properly cleaned before placing the invert segments. These segments shall be embedded in
cement mortar to allow for levelling.
2.8.6
Assignment of risk during TBM excavation

The risks assigned to the Contractor include, but are not limited to the following:
All risks related to mixed-face conditions; the Contractor is expressly made
aware of the extensive mixed-face conditions expected along the tunnel and
shall provide a suitable TBM of robust construction and of proven design for
the anticipated conditions.
Additionally the importance of cutter size selection and of the cutter design is
emphasised for which all risks are expressly assigned to the Contractor.
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All mechanical defects and break-downs of the TBM machinery and
equipment.
All occurring variations in rock mass quality and in rock properties, both
intact rock properties and rock mass properties.
All frequent changes of rock properties and rock mass quality.
Obstruction or interruptions of the loading and transporting operations due to
clogging of the excavated material or the occurrence of large single boulders
or pieces of rock.
Inflow of water and all hindrance to the advance due to water.
The risks assigned to the Owner are the following:
Those risks compensated by the unit prices in the Bill of Quantities and the
regulation of construction time according to Chapter 6 below
The quantities allocated to exploratory drilling, grouting and rock support
2.9
Utilisation of Materials
Excavated materials shall be used for forming of fills or spoiled as approved by

Gener. Unless designated by Drawings or by Gener spoil areas shall be proposed by the
Contractor and approved by Gener. Treatment and works at fill and/or spoil areas are covered
under Specifications for Earthworks.
3.
ROCK SUPPORT
3.1
3.1.1
Scope
Coverage
This Chapter comprises all work intended to support and stabilise the rock
whether of initial or permanent nature, in open cuts or in underground openings.
The Contractor shall provide all material, labour and equipment and carry out all
works, temporary works and tests required for completion of the work.
The Contractor shall assume full and sole responsibility for safe working
conditions for all excavations and the health and safety of all workers and visitors to the work
during the construction period. In addition to provisions for safety included in these
600-TU-ETG-001
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specifications and elsewhere in the Contract, all of Contractors operations shall conform to all
applicable laws and regulations.
3.1.2
3.1.2.1
General
Support work shall be carried out in accordance with the following definitions:
Initial rock support shall mean support work necessary to ensure safe working
conditions and to maintain the shape of the rock excavation during the
construction period.
Additional rock support shall mean all support work necessary to ensure the
permanent long-term stability of the excavations.
"Support work at the face" shall mean all support work interrupting the normal
excavation cycles, except that all support work carried out in caverns (as, for
instance, the powerhouse cavern including busbar tunnels and niches for
transformers) and above ground, in open cuts etc., shall be regarded and
measured as support work behind the face. All support work carried out ahead of
and along the TBM back-up shall be regarded and measured as support work at
face. All support work carried out in RBM-shafts shall be regarded and measured
as support works behind the face.
"Support work behind the face" shall mean all support work not being measured
as carried out at the face.
The rock support consists of combinations of scaling, rock bolts, sprayed
concrete, several forms for reinforcement for the sprayed concrete including lattice girders and
full concrete lining. For TBM tunnels, also circular steel sets are required.
3.1.2.2
Rock Mass Quality Classification
During excavation a rock mass quality classification will be performed by Gener

after each blast (or during TBM boring). To facilitate the work the rock mass quality will be
grouped into five classes as defined in Chapter 2.1.2.2 Rock mass quality classification.
3.1.2.3
Rock Support Classification
The basic Rock Support resources (RS) used for each rock mass category (q)
may in principle be listed as follows:
600-TU-ETG-001
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q1 => RS 1:
Scaling and spot bolts.

TBM/reamed shaft: Scaling and spot bolts.
q2 => RS 2:
Scaling. Spot bolting for smaller cross-sections. Pattern bolting

and spot applied fibre reinforced sprayed concrete for larger
cross-sections.
TBM/reamed shaft: Scaling and spot bolts.
q3 => RS 3:
Scaling. Pattern bolting and minimum one layer of fibre reinforced

sprayed concrete in crown and walls for smaller cross-section.
Number/length of bolts and thickness of sprayed concrete depend
on the cross-section.
TBM/reamed shaft: Scaling, spot bolts and partial use of fibre
reinforced sprayed concrete.
q4 => RS 4:
Pattern bolting and a minimum of two layers of fibre reinforced

sprayed concrete in crown and walls for smaller cross-section.
Occasionally (i.e. on 10 - 20% of the length) reinforced ribs of
rebars/lattice girders and sprayed concrete or concrete lining.
Occasionally concreting of the invert at face could be selected.
Number/length of bolts and thickness of sprayed concrete depend
on the cross-section. Also applies to short blasting rounds and
subdivision of rounds depending on cross-section.
TBM and RBM: No use of concrete lining at the face (circular steel
sets might be installed behind cutterhead).
q5 => RS 5:
Pattern bolting and spiling bolts. Fibre reinforced sprayed concrete

when short stand up time and application of reinforced ribs of
rebars/lattice girders and sprayed concrete at the face and
concrete lining behind the face. Reinforced ribs may be omitted if
concrete lining is cast at the face. Concreting of the invert at face
could be selected. Number/length of bolts and the thickness of
sprayed concrete as well as the distance between the lattice
girders depend on the cross-section. Also applies to systematic
short rounds for small cross-sections and subdivided rounds or
multiple drifts for larger cross-sections.
TBM and RBM: No use of concrete lining at the face (circular steel
sets might be installed behind cutterhead).
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Note that in categories q1, q2 and q3 safety considerations dictate a minimum
thickness of 70 mm fibre reinforced sprayed concrete in roof and abutments in caverns and
other relevant underground openings.
3.2
Reference Standards
The work shall be performed according to relevant standards, or if no standards

exist, the work shall be performed according to recognised practice approved by Gener.
3.3
Submissions by the Contractor
3.3.1
General
Submissions, which the Contractor is required to make to Gener are described
below.
documents:
3.3.2
Documents
The Contractor shall prepare and submit documents in accordance with
Table 3-1.
Table 3-1:
Submittal of documents- Rock Support
Item
Detailed work plan showing procedures for rock support
application
Data sheets and samples for rock bolts and anchors including
accessories, rock straps, ready mixed mortars and admixtures
for grout.
Issue for Issue for

approval
info
*
6F
6F
Data sheets for equipment for application of sprayed concrete

Data sheets and samples for the different types of cement,
fibres, lattice girders, steel sets, chemical admixtures and
micro silica
Rock bolting and sprayed concrete reports including all
records of rock bolting and sprayed concrete performed
Issue
time
*
*
6F
6F
4T
600-TU-ETG-001
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Geners approval does not exempt the Contractor of his sole responsibilities for
3.3.3
Test Reports
The Contractor shall make tests and prepare and submit test reports in
Submittal of test reports Rock support

Issue for Issue for
Item
approval
info
Table 3-2:
Issue
time
Pre-construction test reports as specified
6F
Test reports for all tests during construction
4T
3.3.4
Certificates
The Contractor shall submit manufacturers and suppliers certificates of

compliance with the relevant standards.
3.4
General
3.4.1
Inspection of Tunnels, Marking of Chainage, Wash-down
The Contractor shall inspect rock surfaces jointly with Gener as soon as practical
after excavation. Further, inspections with use of a mobile platform shall be done with no longer
intervals than 2 weeks and shall cover the sections/areas where the Contractor has completed
the bi-weekly scaling during this period.
The Contractor shall clearly mark the chainage of the tunnels for every 10 m. The
chainage marking shall be done with red spray paint on the right tunnel wall, 1.5 - 2.0 m above
the invert. The accuracy of the chainage marking shall be within 250 mm. The maximum
distance between the tunnel face and the last chainage mark shall be 25 m. If the marking due
to wear and dirt becomes difficult to read, it shall be washed and/ or repainted.
Wash-down of excavated surfaces by water flushing shall be done after mucking
of each round.
Gener will regularly after blasting perform geological mapping of the rock mass.
This mapping will normally be done after mucking and will not disturb the Contractors work. In
special cases, Gener will order suspension of excavation works in order to perform more
thoroughly mapping or investigations.
600-TU-ETG-001
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In the TBM tunnels the geological mapping will be performed continuously and
concurrently during excavation. Access for Gener to the tunnel heading/face and machine zone
must be assured by the Contractor.
3.4.2
Rock Support
The aim of rock support is both to provide safe working conditions during
construction and a sufficient long-term stability of the underground opening. Safe working
conditions, both for staff and equipment, which are the sole responsibility of the Contractor, are
to be taken care of by the initial rock support. For long-term stability, extent of additional rock
support will be decided by Gener.
The terms initial rock support and additional rock support are used only for a
classification of rock support works in regard to responsibility for decision making, and may both
occur at the face and behind the face and shall not influence on measurement and/or payment.
The terms at the face and behind the face are used for differentiation of payment of rock
support works.
Initial rock support will normally consist of scaling, end anchored and/or fully
grouted rock bolts, rock straps, wire mesh (and/or fibre reinforced), sprayed concrete or
combination of these methods. In cases of very poor and extremely poor rock mass quality
lattice girders in combination with sprayed concrete will be needed.
In TBM tunnels, also circular steel sets could come into use immediately behind
cutterhead.
Additional rock support will normally consist of fully cement grouted re-bar rock
bolts and/or sprayed concrete with various reinforcement methods. Cast in place concrete lining
might also be required.
The initial support shall be incorporated in the Additional, long-term, support.
Materials for initial rock support shall therefore be of equal quality as for additional support, i.e. a
long-term quality. The Contractor shall inspect rock surfaces jointly with Gener as soon as
practical after blasting/TBM excavation and shall recommend to Gener the type and extent of
initial support. The type, extent and details of support to be installed shall be subject to Geners
consent. Gener may consent to the Contractors proposals or may direct the Contractor to
increase the amount of support or change the type of support as part of the additional rock
support. Gener will define additional rock support prior to completion of the excavation work.
In the tunnels excavated with TBM, the major part of the rock support is
presupposed to be executed in the machine area, between the cutter head and back up. This
includes scaling, installation of rock bolts, wire mesh, steel sets, lattice girders and sprayed
concrete simultaneously with the boring process, without obstructing the TBM operation and
boring process.
600-TU-ETG-001
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The failure of Gener to consent to the Contractors recommendations on rock
support does not exempt the Contractor of his responsibility for the safety of the work. No
statement in this Specification shall be construed to exempt the Contractor from the sole
responsibility for safe working conditions in the underground openings or from liability for injuries
to persons or to damage to property. Consent to a reach as unsupported shall in no way
exempt the Contractor of responsibilities or liabilities and will not preclude Gener from requiring
supports in the reach at a later stage if signs of instability of the rock mass are indicated.
If at any time the Contractor has reason to believe that additional support, beyond
that previously consented to by Gener, may be necessary for the safety and integrity of any rock
surface, the Contractor shall promptly bring the matter to Geners attention together with the
Contractors recommendation as to the type and extent of additional necessary support.
The scheduling for installation of rock support shall be the responsibility of the
Contractor, and is subject to the consent of Gener. Additional rock support shall be installed
behind the tunnel face where the work does not cause delays in the excavation progress.
Gener might in special cases request such support to be applied at or immediately behind the
working face.
If the Contractor considers it necessary to request excavation outside the
theoretical contour to obtain access for temporary works or installations, such request shall be
forwarded to Gener, and the work, including all initial as well as all additional support, shall be at
the Contractors cost and time. Gener may also require such excavations backfilled with
concrete, at the Contractors cost and time.
3.5
3.5.1
Scaling
General
Scaling works are classified into basic scaling and additional scaling and
comprises also tunnels excavated by TBM.
Basic scaling and additional scaling are to be performed in accordance with the
best prevailing practice. It is required that the Contractor keeps available equipment in efficient
working order for the scaling works, such as:
scaling rods,
scaling platform to be mounted on shovel (or other lifting equipment),
hydraulic scaling hammer to be mounted on the boom of an excavator,
equipment for cleaning/scaling by high-pressure water flushing.
600-TU-ETG-001
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3.5.1.1
Basic Scaling
Basic scaling is included in the excavation cost and procedures and covers
scaling at the face, bi-weekly scaling and final scaling as follows:
a)
Scaling at the face:

Defined as a routine scaling after each blasting round, in order to comply
with the safety requirement and requirement of surface treatment, before
application of sprayed concrete.
b)
Bi-weekly scaling:
All scaling needed in walls and roof for the section excavated during the
last 2 weeks, plus an overlap of 30 m of the former bi-weekly scaling
section. A measure for completed scaling is that there are no stones larger
than 0.001 m3 (1 dm3) which are possible to remove by manual use of
scaling rods, or as instructed by Gener. If the bi-weekly scaling is not
performed satisfactorily, Gener may request the blasting works stopped
until the scaling is found acceptable.
c)
Final scaling:
Before handing over the Works, a final scaling shall be performed prior to
release of the work site for other activities. The required level for completed
scaling is as described under b).
3.5.1.2
Additional Scaling
Additional scaling is scaling ordered by Gener.

d)
Extra scaling:
Extra scaling comes in addition to the basic scaling in order to comply with
the requirement defined under b), at the face or behind the face.
e)
Invert cleaning and scaling:

Removal of temporary road dressing material, scaling of rock with scaling
rods, and high-pressure water flushing, 20 mm nozzle and minimum
pressure 10 bar. Max. 0.001 m3 remaining loose materials accepted per 5
m2 of tunnel invert.
f)
Chisel scaling:
All loose and drummy rock (hollow sound) is to be removed to the degree,
which is possible by chisels.
g)
High-pressure water flushing of rock surface:
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All loose rock is to be removed to the degree possible by high-pressure
flushing with combined water and air, 20 mm nozzle and minimum
pressure 10 bar.
3.6
Rock Bolts and Accessories
3.6.1
Materials
Rock bolts of the following types may be used:
Resin end-anchored bolts (deformed steel bars)
Fully grouted deformed steel bars
Fully grouted expansion-shell bolts (deformed steel bars)
All bolts shall serve as permanent support and shall normally be fully grouted with
cement mortar, but resin end anchored and fully resin-grouted bolts may be approved as
permanent support, if corrosion protected in accordance with clause b in the list below. Gener
shall approve all bolt types to be proposed and used by the Contractor. Permanent rock bolts
shall conform to the following requirements:
a)
Deformed steel bars and plain steel bars shall conform to ASTM A 615M,
Grade 4500 having minimum yield-point strength of 500 N/mm2.
b)
Corrosion-protection with hot-dip zinc coating (minimum 80 micron) shall

conform to ASTM A 767 alone or in combination with epoxy coating conform
to ASTM A 775 or similar. Bolt accessories shall be provided with the same
corrosion protection as the rock bolt.
c)
Threaded rock bolts shall be provided with rolled threads of min. 150 mm
length of the same corrosion protection or better than the bolt itself. The
threaded part shall withstand a force equal to the actual ultimate load of the
rebar. If the threaded part is separate and to be connected to the rock bolt,
the rock bolt and the threaded part shall be connected by friction welding
according to BS 6223. The friction weld shall have the same corrosion
protection or better than the bolt and threaded part. The friction weld shall
withstand a force equal to the actual ultimate load of the rebar.
d)
All type of bolts shall be provided with a 200 mm diameter dished anchor
plates of 6 mm thickness, semi-spherical washers and nuts. The assembly
shall adjust to angular displacement from normal up to 45. The steel quality
of the anchor plates shall conform to ASTM A 36/A 36M. Other accessories
shall be of steel quality compatible with the quality of the rock bolt.
Bottom part of bolts for end-anchoring with polyester resin anchoring shall be
provided with a spring or other device for efficient mixing of the polyester resin.
600-TU-ETG-001
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Polyester resin capsules shall be of quality giving sufficient bond strength to
comply with requirements for pull tests.
The cement mortar used for grouting of rock bolts shall comply with the following
requirements:
Shall not react chemically with zinc coating.
Expansion 1 - 3 %, to be completed before completed hardening of the
grout.
Max. grain size 0.5 mm.
Compressive strength min. 45 MPa at 28 days.
Resin end anchored bolts shall be hot-dip zinc and epoxy coated. Fully grouted
rock bolts shall as a minimum be hot dip zinc coated. Additional epoxy coating will be required
unless the grouting material for bolting has been verified not to cause undesired chemical
reactions with the zinc coating.
The tensioning of all the rock bolts in the corresponding reach shall be checked
as part of the bi-weekly scaling. In case of loose bolts, the bolts shall be re-tensioned. In case
of overbreak around other bolts ends, re-drilling and/or resetting of bolts shall be done.
3.6.2
Accessories
The Contractor shall provide all necessary accessories, additional boreholes

where required or other items necessary for installation and anchoring or grouting of the bolts.
Chain linked mesh, welded wire fabric and steel straps with necessary
accessories will be required in special cases. All such materials shall have double corrosion
protection (combi-coat or equivalent), complying with clauses above if used aboveground. For
underground works the corrosion protection shall be as specified in the B of Q.
The dimensions are (in millimetres):
Chain-linked mesh:
50 x 50 x 2.7/3.0
Welded wire fabric:
150 x 150 x 6.0
Steel straps: Max openings/min. bar diameter
50 x 300/10
Chain linked mesh shall be removed prior to commissioning as directed by

Gener. Welded wire fabric not covered by sprayed concrete shall be removed prior to
commissioning or as directed by Gener.
600-TU-ETG-001
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3.6.3
Execution
3.6.3.1
Drilling and Installation of Resin End-anchored Bolts
Resin-end anchored bolts shall be installed in accordance with the written

instructions issued by the manufacturer.
The bolts shall have an anchored length of minimum 250 mm in high strength
rock types (unconfined compressive strength, UCS, >150 MN/m2) and 500 mm in medium
strength rock types (50<UCS< 150 MN/m2). For low strength rock types the minimum anchored
length shall be 1 m. The diameter of the boreholes' inner end shall be 10 to 12 mm larger than
the bolt diameter.
The bolts may be installed in a systematic, predetermined pattern, or as spot
bolts.
3.6.3.2
Drilling and Installation of Fully Cement-grouted Bolts
Fully grouted deformed steel bars with or without expansion shell end anchoring
shall be installed in accordance with the following instructions:
a)
Rock bolts may be installed in a systematic and predetermined pattern, or

as spot bolts as directed by Gener. Rock bolts shall be installed
perpendicular to the rock perimeter, or otherwise as directed by Gener.
b)
The diameter of the drill holes shall be minimum 15 mm and maximum

35 mm larger than diameter of the rock bolt.
c)
Drill holes shall be flushed with water for their entire length before grouting.
d)
Rock bolts shall be cleaned to remove dirt, grease or any other impurities
before installation.
e)
The entire hole shall be filled with a mortar (grout) before installation of rock
bolt.
f)
In upward slanting boreholes measures shall be taken to prevent loss of

mortar. The bolt shall then be secured by wedges or other means to
prevent movements during hardening of the mortar.
g)
Bolt ends shall not protrude more than 50 mm outside nuts if not otherwise
decided by Gener.
h)
Anchor plate, washers and nuts may be located outside or within the
reinforced sprayed concrete. In conjunction with welded wire fabric or rock
straps, the rock bolts shall be installed in depressions of rock surface if
possible.
i)
j)
3.6.4
600-TU-ETG-001
41
The nut of grouted rock bolts shall be tightened to achieve a force at anchor
plate of approximately 20 kN. Tightening can be carried out when minimum
2 MPa grout strength has been obtained.
For grouted expansion-shell bolts, the maximum working load shall be
limited to 50% of the ultimate load, when pre-stressed before grouting.
These bolts shall be installed in accordance with the manufacturer's issued
written instruction.
Testing
3.6.4.1
General
Documentation of properties of grouts to be used for grouting of rock bolts shall

be submitted to Gener. The grout properties to be documented will comprise, but are not limited
to, consistency, setting time, strength after 1, 7 and 28 days, porosity, expansion and
permeability of hardened grout.
The Contractor shall fill in Quality Control forms which state type of rock bolts and
accessories, condition of corrosion protection, installation method and tensioning.
The Contractor shall perform quality control of rock bolt installation according to
the Quality Control Procedure described by Gener. Geners control engineer shall have free
access to participate in the quality control.
End anchored rock bolts are to be tested by pull test. Installation procedure for
grouted rock bolts is to be verified by test grouting of rock bolts in plastic tubes.
The following control categories will be included in the Quality Control Procedure:
Category I - Visual control of bolts and accessories
Visual control of corrosion protective coatings on rock bolts and accessories prior
to installation. In case of any damage to epoxy/ polyester coating, mending is to
be performed with a result complying with the requirements for epoxy/polyester
coating. In case the damage penetrates the zinc layer, rock bolts or accessories
will not be accepted.
Category II - Pull tests
By use of hydraulic jack with a pull force of 80 % of the yield strength. Required
number of tests for a given bolted area and required number of acceptable
results for approval of the bolted area are defined below.
Category III Test grouting of bolts in plastic tubes
600-TU-ETG-001
42
This test shall be performed concurrent with the bolting of a defined area or
tunnel interval. Assessment of number of test bolts is described below.
The same number of tubes with internal diameter equal to the hole diameter, are
mounted in a rack, and test bolts are inserted and grouted with use of the same
grout and the same method as for the rock bolting.
After 10 hours of hardening, the plastic tube is removed for control of how well
the bolt is covered by concrete. If less than 95% of the bolt surface within the
tube is covered by grout, that bolt shall be rejected.
The number of accepted test bolts required for approval of the given area or
tunnel interval is defined below.
3.6.4.2
Criteria for Assessment of Test Numbers and Acceptance of Test

Results
The method for selection of test bolts shall comply with International Standard
ISO 2859-1 Sampling procedures and tables for inspection by attributes. Gener will define the
areas or the tunnel reaches to be tested. Gener will define bolt groups in the order of 200 to 500
bolts as lot sizes for the inspection (testing). Assessment of sample size will be done in
accordance with ISO 2859-1, Table I, general inspection level II. A lot size of 151 - 280 bolts
requires a sample size G of 32 bolts for normal or tightened control, or of 13 bolts for reduced
control.
Evaluation of results will be in accordance with Table IIA (single normal control)
or Table IIB (single tightened control), with Acceptable Quality Level AQL 2.5. With normal
inspection (testing), this requires that a size G sample does not have more than 2 test failures.
Switching from normal to tightened control will be done (according to ISO 2859-1) when two out
of five or less tested lots have been non-acceptable on original inspection (that is, ignoring resubmitted lots or batches for this procedure). With tightened control only 1 test failure is
accepted for sample size G. When tightened inspection is carried out, normal inspection shall
be reverted to when five consecutive lots have been considered acceptable on original
inspection. Procedures for switching from normal to reduced testing and from reduced to
normal testing are described in ISO 2859-1.
3.6.4.3
Measures to be taken in Case of Rejection and Re-bolting
If the test results for a defined group of end anchored rock bolts do not satisfy the
requirements, control of all bolts in the group will be required. All bolts which do not pass the
pull test; with a pull force of 80% of the yield strength is the Contractors responsibility and will
have to be replaced by the Contractor.
600-TU-ETG-001
43
If the test results for a given group of grouted rock bolts do not satisfy the
demands defined by AQL 4.0 in ISO 2859-1, the prices for the bolts in that group will be reduced
with 25%, and Gener will require additional bolting to correct the deficiency in quality.
3.7
Spiles
Reinforcing of the rock mass ahead of the tunnel face with long bolts (spiles) is
termed spiling. This support system may be applied for particularly unstable rock conditions, to
restrict deformations of the surrounding rock, and to prevent cave-ins following the next rounds.
The spiling holes shall be drilled from the perimeter of the tunnel face, slanting
outwards into the rock surrounding the tunnel stretch to be excavated. In TBM tunnel, the holes
are drilled from immediately behind cutterface see clause 2.8.
Deformed steel bars shall be placed in the holes and fully grouted.
The spile length is governed by the length of the round and the minimum spile
length is 2 times the length of the round.
Spacing and inclination of the spiles shall be as agreed upon by Gener.
Rock straps shall be combined with the radial bolts for securing protruding ends
of spiles against vibrations and overbreak.
Spiles are subject to quality requirements as specified for rock bolts above.
3.8
Rock Anchors
If required by Gener the Contractor shall install permanent rock anchors. The
needs of such anchors will be evaluated when the geological conditions have been assessed.
Bar tendon rock anchors will be single bar anchors, min yield strength 800 kN..
Strand tendon rock anchors will be St 1570/1770 DYWIDAG or equivalent. The anchors shall
be adequately corrosion protected by a "double system" as recommended for permanent
anchors by the supplier and approved by Gener.
Grouting and installation of rock anchors shall be performed according to the
manufacturers prescriptions. The active anchors shall be pre-stressed to 75% of yield strength.
Quality control shall be included as specified by the supplier for permanent
anchors.
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The Contractor shall with his Tender present information on the type of anchors
he proposes to use. He shall at the request of Gener present a detailed methods statement for
the drilling, grouting, testing and fixing of the anchors.
3.9
Sprayed Concrete
3.9.1
General
For general concrete specifications reference is made to Specifications for

Concrete works. Supplementary specifications relating to rock support are given below.
Sprayed concrete shall be applied plain or reinforced by steel fibres as directed
by Gener. Only robots and wet mix method (as defined in EFNARC, (European Specification for
Sprayed Concrete), Section 3) shall be used. All plant and methods for spraying shall be
approved by Gener. Application of sprayed concrete shall be carried out by experienced
operators only.
The sprayed concrete equipment shall include a robot furnished with a boommounted nozzle operated by remote control in order to allow operators to always work from a
protected and safe place. The theoretical pumping capacity for each equipment shall be
minimum 20 m3/hour.
The Contractor shall keep equipment at site able to catch the rebound material, in
order to measure the quantity of it (by weight).
For programmed work, the Contractor shall inform Gener about the location of
areas where sprayed concrete is to be applied at the latest 12 hours in advance. When sprayed
concrete is applied as initial support in tunnels, Gener shall be informed at the latest 1 hour in
advance.
In cases where a major part of the surface is to be covered by sprayed concrete,
sufficient time shall be allowed for Gener to record the geological features before the application
of sprayed concrete takes place.
3.9.1.1
Composition
a)
Portland Cement Type I, complying with ASTM C 150 Portland Cement,

shall be used. Requirements are given in Specifications for Concrete works.
The minimum cement content for a particular environmental condition shall
be as required by EFNARC Section 6.4 and EN 206. The total Alkali content
in the mix shall be less than 5.0 kg/m3.
b)
Micro silica (silica fume) may be included in the mix for improvement of
pumpability and to obtain more cohesive consistency, but not more than
600-TU-ETG-001
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10% by weight of the Portland clinker content. This limit also applies to
other admixtures with correspondingly high pozzolanic effect, and also to the
total content of such materials. The total contents of such materials and
other types of pozzolana directly mixed into the cement and added during
concrete production shall not exceed 25% of the total weight of Portland
cement and pozzolanic materials, including silica fume. Fly ash, if used,
shall meet the requirements in ASTM C618, and shall be tested and
reported accordingly. Pozzolana shall be ordered, handled and stored
similarly to cement.
c)
When sulphate content in ground water exceeds 150 ppm, sulphate

resistance may be achieved by achieved by the use of micro silica (minimum
5 percent, maximum 10% of the cement weight) and a low ratio (0.45) of:
(water) / (cement + silica)). The amount of water in the concrete includes
added water, sand moisture and water from additives, silica slurry etc.
d)
The aggregate shall be a wellgraded sand with a maximum content of 10%

(by weight) of grains with sizes larger than 8 mm. Maximum particle size
shall be 12 mm. The aggregates shall meet the requirements given in
Specifications for Concrete works.
e)
Admixtures and other materials for concrete shall be so selected that the
total content of chlorides does not exceeds 0.4% by weight of the Portland
clinker. The admixtures shall meet the requirements given in Specifications
for Concrete works. Full account should be taken of their effect on the
finished sprayed concrete and there should be sufficient data about their
suitability, including previous experience with such materials. Records
concerning details of the performance of such admixtures shall be
maintained.
f)
To avoid damage due to alkali-silica reaction one of the two following

measures shall be taken:
Use an aggregate, which by testing at an approved laboratory has

proved not to be susceptible to destructive attack by alkalis.
Limit the alkali content of the concrete mix, accumulated from all sources
to 3.0 kg/m3 of Na2O equivalent.
At the earliest possible time, the necessary trial for sprayed concrete mix design
shall be batched, applied and tested according to the standards referred to below for Gener's
approval of the mixes and methods to be used.
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3.9.1.2
Requirements for Sprayed concrete
The sprayed concrete mix shall be designed by the Contractor in accordance with
EFNARC Section 7.
Unless otherwise specified, the strength grade of sprayed concrete shall meet the
requirements of concrete strength class H-40 (NCh170 Of85) and the condition of environmental
exposure shall be Moderate, both according to EN 206. To determine that the concrete meets
the requirements to compressive strength, the in-situ strength requirements given in Table 9.1.2
of the EFNARC Specification shall be met, which are based on a 50 mm diameter by 100 mm
long core and include a 0.85 reduction factor to allow for effects of in-situ curing, the sprayed
concrete operation itself and the use of accelerator (rapid hardening agent).
Unless otherwise specified, the rate of hardening should be:
At 24 hours:
30 percent of final strength
At 7 days:
At 28 days:
Fibre reinforced sprayed concrete of strength class H-40 (NCh170 Of85) used for
ordinary rock reinforcement shall have a flexural strength of minimum 3.95 MPa as specified in
EFNARC Section 9.2.
The toughness requirements of the fibre reinforced sprayed concrete of strength
class H-40 (NCh170 Of85) shall comply with residual strength class 2 as given in Figure 9.3.1
and Table 9.3.1 of the EFNARC Specification. Testing shall be in accordance with the
description of the beam test as given in EFNARC Section 10.
Gener may order adjustment of the mechanical parameters of sprayed concrete.
Documentation of these properties will then be required.
3.9.1.3
Methods/Execution
Sprayed concrete shall be applied plain or reinforced as shown in the drawings or

agreed between Contractor and Gener.
Before commencement of work the crew shall be instructed so as to obtain a
sprayed concrete quality, which is in accordance with the Specification and requirements made.
Gener may require that a volume estimate shall be made prior to application of
sprayed concrete on an area, based on the specified average thickness and the roughness
factor of the rock surface. The roughness factor is empirical and gives an overall characteristic
of the actual rock surface divided by the theoretical area. It takes into consideration the volume
required to fill hollows and cracks. Furthermore, it may vary depending on the sprayed concrete
600-TU-ETG-001
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thickness, resulting in a higher value for thinner layers. The Contractor and Gener shall jointly,
prior to spraying of the area, decide on the roughness factor and agree on the required volume
to produce the specified thickness. The estimated volume shall also compensate for the
assumed volume of rebound. Additional sprayed concrete shall be applied if measurements
show that the rebound quantity deviates considerably from the assumed value.
The distance between the nozzle and the application surface shall be in the range
of 1.0 to 2.0 m. The nozzle position shall be at right angles to the application surface. Any
crevices shall be filled first. All surfaces to be sprayed shall be thoroughly scaled and then
cleaned by water flushing and, if required, by sand blasting until they are free of dust, all traces
of dirt, oil, grease, rebound material or other harmful matter. Curing membranes of a type that
may affect the bond strength when applying additional layers shall also be removed. Surface
preparation may be omitted in very poor rock mass quality.
The surface shall be kept moist, but not wet, until the sprayed concrete is applied.
If water occurs on the surface to be sprayed, a decision must be made whether spraying shall
take place or the leakage is to be grouted or drained.
The sprayed concrete shall be kept moist for at least 7 days by water sprinkling or
covering. On final surfaces a curing membrane shall be used if the curing conditions are
deemed unsatisfactory. Any curing compound shall comply with EN 206. Rapid drying at the
end of the curing period is to be avoided. Natural curing may be considered if the atmospheric
conditions surrounding the sprayed concrete are satisfactory, i.e. sufficiently high relative
humidity.
All rebound sprayed concrete and all overspray shall be removed upon
completion of the sprayed concrete process.
3.9.1.4
Thickness
When a specified thickness is stated, the sprayed mean thickness shall be at

least the specified thickness. The sprayed minimum thickness on protruding rock shall be at
least 50% of the specified thickness.
3.9.1.5
Testing and Control
Testing of sprayed concrete with or without steel fibre reinforcement, applied for
general rock support, shall be carried out as Normal Control Class according to the methods
and with frequencies as specified in EFNARC Sections 10 and 11, if not otherwise specified or
instructed. Quality control and documentation of sprayed concrete applied for this purpose shall
be executed in accordance with EFNARC Section 11.
No differentiation is made between sprayed concrete used for initial or permanent
support.
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The bond shall be checked at random by knocking on the sprayed concrete with a
scaling rod. A dull response (hollow sound) indicates areas of no bond. The control shall be
documented by a written report and carried out at a frequency of at least one knock per 5 m2.
Areas of dull response shall be clearly marked and Gener shall make an assessment of
additional support required, which shall be performed at the Contractor's expense. The
checking shall be carried out covering the total area of sprayed concrete. The bond requirement
does not apply in fault zones and in highly weathered rock mass.
The thickness shall be checked by drilling through the hardened concrete in a grid
of 2.0 x 2.0 m, or by fixing nails to the rock surface in a grid of 2.0 x 2.0 m. Points shall be
located at both hollows and at high points. The number of points shall be at least 25. The
frequency of thickness testing shall be as per each 300 m2 of sprayed concrete if not otherwise
agreed with Gener.
The control of fibre content shall be carried out from cored specimens in
accordance with EFNARC Section 10.9.1. The test shall be carried out for each sprayed
volume of 100 m3 fibre-reinforced sprayed concrete.
3.9.1.6
Documentation
Minimum 2 weeks before commencement of any sprayed concrete work, the

Contractor shall submit for Geners approval applicable data for fibres, cement and admixtures
for the sprayed concrete.
Reporting on testing shall be executed according to the applicable standards (and
the agreed Quality Plan.)
3.9.1.7
Reinforcement of Sprayed Concrete
Materials
The following types of reinforcement for sprayed concrete may be used:
Steel fibres of approved type conforming to ASTM A 820, with a minimum
fibre length of 18 mm and an aspect (length/thickness) ratio >40. The length
of the steel fibres shall not exceed 0.7 of the internal diameter of the pipes or
hoses used unless a test has proven that longer fibres can be sprayed
without blockage.
Welded wire fabric of dimensions 150 x 150 x 6.0 mm. Corrosion protection
and concrete cover thickness to be specified in each particular case.
Synthetic fibre reinforcement shall only be used as approved by Gener.
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Reinforcement for sprayed concrete ribs shall be one of the following two types:
Deformed rebars of minimum 16 mm diameter tied together by transverse
pieces of deformed rebars of minimum 20 mm diameter. The transverse ties
shall be fixed to radial rock bolts.
Prefabricated lattice girders made from deformed rebars shall be bolted to
the rock surface. The girders shall comply with the following requirements:
Section modulus
Wx > 75 cm3
Height
hmax = 200 mm
Chain linked mesh is not acceptable as sprayed concrete reinforcement.

3.9.1.8
Method/Execution
Steel fibres shall be added according to the achieved results from the testing of
trial mixes complying with the specified toughness/flexural tensile strength requirements. Steel
fibres shall be stored in a dry environment. Corroded steel fibres shall not be used.
Before mounting welded wire fabric the first layer of sprayed concrete shall be
applied in order to smooth the surface. Welded wire fabric shall be installed so that it follows
irregularities of surface closely and with one pitch of overlap. Additional bolts shall be used for
fixing of welded wire fabric. At least one fixing point per 2.5 m2 shall be used. For two layers of
welded wire fabric reinforcement separate bolts shall be installed for each layer. If more than
one layer of welded wire fabric is used, a minimum of one layer of sprayed concrete is required
between the layers. Welded wire fabric shall be covered by a minimum 50 mm thick sprayed
concrete layer to provide satisfactory corrosion protection.
Rib- or lattice girder reinforcement shall be installed in accordance with given
profile lines and as close to the actual rock surface as possible. Prior to installation, the rock
surface shall be covered by a minimum of 60 mm thick fibre reinforced sprayed concrete.
Girders shall be fixed to the rock by means of rock bolts. The girder sections shall be bolted
together.
Sprayed concrete shall be used to ensure a good and evenly distributed load
transfer. Blocking and wedging will not be permitted.
600-TU-ETG-001
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3.10
Cast in place Concrete Rock Support
3.10.1
Scope
The operation encompasses all activities and deliveries necessary for the
installation of concrete structures for rock support purposes, including but not limited to:
Delivery of formwork material, reinforcement material, concrete etc.
Execution of necessary scaling, formwork, reinforcement, concreting,
removal of formwork, curing precautions etc.
Formwork, as required, shall be provided by the Contractor.
3.10.2
Materials/Equipment
3.10.2.1
Materials and Admixtures for Concrete
The following requirements apply:

a)
Portland Cement Type I, complying with ASTM C 150 Portland Cement,

shall be used (see Specifications for Concrete works.).
b)
Pozzolanic admixtures may be used after Geners approval. The total

content of such materials directly mixed into the cement and added during
concrete production shall not exceed 35% by weight of the cements total
content of Portland clinker and pozzolana. Silica fume may constitute a part
of the pozzolanic materials, but not more than 10 percent by weight of the
Portland clinker content. This limit also applies to other admixtures with
correspondingly high pozzolanic effect, and to the total content of such
materials.
c)
When the sulphate content in ground water exceeds 150 ppm, sulphate
resistance shall be ensured by the use of microsilica (min 5% and maximum
10%of cement weight) and a low ratio (
The water ratio includes added water, moisture in the aggregates, slurry etc.
d)
The mixing water shall meet the requirements given in Specifications for
Concrete works.
e)
The aggregates shall be in accordance with the requirements given in

Specifications for Concrete works.
f)
Admixtures and other materials for concrete shall be so selected that the
total content of chlorides does not exceed 0.4 percent by weight of the
Portland clinker. See Specifications for Concrete works.
g)
To avoid damage due to alkali-silica reaction one of the two following

measures shall be taken:
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Use an aggregate, which by testing at an approved laboratory has proved
not to be susceptible to destructive attack by alkalis.
Limit the alkali content of the concrete mix, accumulated from all sources to
3.0 kg/m3 of Na2O equivalent.
At the earliest possible time, the necessary trial concrete designs shall be
batched and tested according to the standards referred to below, for Geners agreement of the
mixes and methods to be used.
3.10.2.2
Reinforcement (if applicable)
The reinforcement material shall be in accordance with ASTM A185 and ASTM A
615M, as applicable.
3.10.2.3
Concrete Grade and Strength Requirements
The concrete mix shall be designed to meet the requirements of the exposure
conditions according to BS 8110.
Unless otherwise specified, the condition of exposure shall be Moderate and the
concrete compressive strength shall meet the requirements of grade H-35 concrete (NCh170
Of85) according BS 5328. Unless otherwise specified, the rate of the hardening shall be:
At 24 hours
30 percent of final strength.
At 7 days
At 28 days
3.10.2.4
Methods/Execution
Normally, plain concrete shall be used, but reinforcement may be called for,
depending on circumstances. The minimum thickness of the concrete shall be 300 mm, unless
otherwise specified.
It may be required that the rock surface shall be trimmed so that a reasonable
homogenous thickness of the concrete is ensured (see comments under sprayed concrete).
Where no specific requirements exist, the concrete contour shall not be situated more than
200 mm inside the planned excavation contour.
Loose material shall be removed from the invert along the walls, so that the
concrete support footing rests on rock.
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If concrete rock support at the face is decided, concreting shall be carried out
immediately after mucking out.
3.10.3
Tolerances
The position of completed concrete surface shall not deviate more than +/50 mm from the planned position.
3.10.4
Testing and Control
3.10.4.1
General
Testing of concrete shall be carried out according to the methods and with
frequencies specified below. Quality control and documentation are of the following types:
Concrete production control.
Materials control prior to concreting.
In situ product control (if applicable).
3.10.4.2
Production Control
Production control includes:

materials and proportioning
aggregate moisture
concrete temperature
consistency
Control procedure shall be prepared in each particular case. Production control
shall be carried out for each shift of concrete works.
When using ready-mixed concrete, the production control may be deleted
provided that the manufacturer can document adherence to the requirements.
3.10.4.3
Materials Control prior to Concreting
Materials control carried out on site shall consist of measurements of the

following parameters:
Concrete temperature.
Consistency.
Pore volume and density.
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53
Compressive strength.
Test Frequency.
The testing frequency shall be as indicated in
Table 3-3:
Table 3-3:
Test frequency
Test
Frequency
Temperature and consistency
Once per shift
Pore volume and density
Occasionally, bur at least at start of each concreting period.

Pore volume only when additives are used.
Compressive strength
Each mix shall be tested once per concreting period, but at

least once per each 250 m3 concrete, totalling minimum of 5
tests.
Control and testing procedures shall be prepared in each particular case referring
to relevant standards. For determination of consistency and compressive strength BS 1881
shall apply.
3.10.5
Documentation
A minimum of 2 weeks before commencement of any concrete work, the

Contractor shall submit for Geners approval applicable data for cement and admixtures for
concrete, as well as proposals for design mix for the various concrete qualities.
Reporting on testing shall be executed according to the applicable standard and
the agreed Quality Plan.
Unless otherwise specified, the condition of exposure shall be Moderate and the
concrete compressive strength shall meet the requirements of grade H-35 concrete (NCh170
Of85) according to BS 5328.
4.
INVESTIGATION AND INSTRUMENTATION DURING CONSTRUCTION

4.1
4.1.1
Scope
General
An investigation program for determination of geotechnical and geological

conditions is foreseen to be performed concurrent with the work. Monitoring and verification of
soil- and rock mass conditions and behaviour during construction will be required.
600-TU-ETG-001
54
Information on rock mechanical conditions is important for location and orientation
of caverns, shafts, concrete plugs and transitions from steel lined to unlined waterways etc.
During tunnel excavation, drilling of exploratory holes for rock mechanical testing will therefore
be performed from tunnels as requested by Gener. The rock mechanical testing shall be done
by professionals co-ordinated by the Contractor and subjected to Gener's approval. The rock
mechanical testing will consist of rock stress measurements done by hydraulic fracturing and
jacking methods, as well as other measurements. The Contractor shall be responsible for all
specified services during the testing.
The Contractor will be allowed to continue work during testing, but restrictions on
blasting close to the test site may apply. Results from rock mechanical investigations will be
used by Gener to verify the detailed design. The Contractor shall be prepared for changes in
the layout/orientations of tunnels, caverns and shafts.
Possible items of instrumentation and monitoring to be supplied for surface and
underground works are listed as follows:
Surface works: Drilling investigations, ground water monitoring, piezometers,
joint meters and surface settlement monuments.
Underground works: Hydraulic fracturing and jacking, 3-dimensional stress
measurements, convergence stations, extensometers and piezometers.
The Contractor shall supply, install and maintain instrumentation in satisfactory
operation during construction. At completion, the instrumentation system shall be turned over to
Gener in satisfactory operational condition.
The results obtained from the instrumentation installed will provide parameters
necessary for the continuous evaluation of the works stability. It is therefore a requirement that
the installation and monitoring of instruments and other observations be given priority.
Should assessment of the performance of the excavations or of the structures
through the reading of instruments demand it, appropriate measures shall be taken by
Contractor, which could include, but is not limited to, provision of additional support, additional
instrumentation and/or special excavation methods.
4.1.2
Coverage
The scope of the works to be performed by the Contractor includes furnishing all
labour, materials and equipment and the performance of all work necessary for supplying,
installing and monitoring all items as specified herein. The work also includes submittals of
reports, packing, handling and transportation of samples and necessary assistance during
600-TU-ETG-001
55
testing performed by expert teams co-ordinated by the Contractor and subject to Gener's
approval.
4.2
Reference Standards
Particular standards relevant for this Chapter are listed below.
If no standards exist, the work shall be performed according to recognised

practice approved by Gener.
American Society for Testing and Materials (ASTM)
ASTM- D2113
Standard Practice for

Diamond core drilling for site investigation
European Committee for Standardization (CEN)

EN 1997-2
Geotechnical design - Part 2:

Design assisted by laboratory and field testing
British Standards Institution (BS)

BS 5930
Code of Practice for Site Investigations
BS 4017
Core Drilling Equipment
International Society for Rock Mechanics (ISRM)

ISRM
4.3
Suggested Methods for Rock Stress Determination, 1987.
Submittals by the Contractor

Submittals that the Contractor is required to make to Gener are described below.
documents:
4.3.1
Documents
The Contractor shall prepare and submit documents in accordance with
Table 4-1.
600-TU-ETG-001
56
Table 4-1:
Submittal of documents Investigation and instrumentation
Issue for
Issue for
Documentation
Issue time
approval
info.
Organisation plan for the Works showing the
*
6F
responsibilities and the Qualifications of the personnel
Data sheets for instruments and procedures for
*
6F
installation and monitoring
Log of all drilled holes
1T
Geners approval does not exempt the Contractor of his sole responsibilities for
4.3.2
General
The Contractor shall at any time during the progress of the Works provide and
maintain adequate equipment and materials with stand-by reserves to be able to carry out the
work ordered by Gener. Specialist personnel with relevant experience shall be employed for the
work.
The Contractor shall keep continuous records and logs of all drilled holes,
instruments, test- and monitoring results. The results shall be presented daily or weekly as
decided by Gener.
Contractor shall provide mild steel covers firmly fixed to the rock/sprayed
concrete/concrete surface to protect all instrument heads from damage during subsequent work.
Should damage occur, the Contractor shall immediately replace the damaged
equipment.
4.3.3
4.3.3.1
Core Drilling and Water Pressure Testing

General
The water used for drilling and testing shall be of potable water quality or as
approved by Gener. For drilling through overburden, slurry suspension may be approved by
Gener.
The drilling fluid shall not be contaminated by oil or grease from pumps, drill rod
couplings or any other source.
600-TU-ETG-001
57
4.3.3.2
Drilling Equipment
Rigs:
It is required that the Contractor shall be able to drill 1 hole at a time and
shall have submitted with his Tender a Core Drilling Equipment Data Sheet,
giving the type, production year and technical details for the core drilling
equipment he intends to use.
The drill rigs shall have a capacity for core drilling at least 200 m in any
direction with a hole diameter of 76 mm. It shall have the possibility for
down-the-hole-hammering to a depth of 100 m, min diameter 76 mm. The rig
shall be fully hydraulic and have the possibility for automatic lifting,
unscrewing/screwing and lowering of drill rods (ATLAS COPCO DIAMEC
26, or similar rig). The rig shall be kept at the site for the duration of the
works.
The rig shall be used at any location, in the tunnels as well as for surface
works.
Drill rods:
The drill rods shall be with O-rings and suitable for internal water pressures
of at least 30 bar.
Recovery equipment:
Core recovery equipment shall be double tube ball-bearing swivel type core
barrels with the core-lifter located in the lower end of the inner barrel.
4.3.3.3
Core Boxes
The Contractor shall provide sturdy core boxes for the protection and storage of
cores.
A core box shall have an inside length of 1.05 m and be provided with longitudinal
separators for storing of 5 core columns and have a hinged lid.
Core boxes with different internal partition widths shall be provided to suit
different core sizes. Normally cores will be placed in boxes of the appropriate size. The
remainder of the trays in a box holding larger diameter core may be filled with smaller diameter
core provided that wooden packing pieces of the correct thickness shall be available for use
alongside the smaller diameter core to prevent rolling within the tray. If a length of core does not
fill a section of the box, square section wooden spacers painted blue shall be available to
prevent the core sliding in the box.
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58
Additional square section wooden spacers painted different colours shall be
provided for placing in the trays to indicate drill runs, samples and core loss.
4.3.3.4
Measuring Equipment
Core orientation and direction survey equipment

The Contractor shall provide suitable instruments to the satisfaction of Gener for
core orientation, deviation and inclination surveys. This latter equipment shall
have a diameter so as to enable deviation measurements in pilot holes for shafts.
4.3.3.5
Water Pressure Testing
Tests
Gener will order water pressure tests to be made and test procedure to be used.
These tests shall be carried out generally in accordance with BS 5930 and the
results shall be recorded on report forms approved by Gener.
a)
Testing concurrent with drilling:

The test shall be carried out by pumping clean, sediment free water
generally into three or six metre test stages while the hole is advancing and
using a single packer. The accuracy of test shall be checked every 4 or 8
tests by sealing off and testing a longer stage on which three or four
shorter stage lengths have been previously tested.
b)
Testing after finished drilling:

Testing starts at the top of the hole, and the single packer is pushed into
the hole in stages of 5 m until zero leakage is measured or hole bottom is
reached. Gener may direct alterative testing with double packers
Equipment
The Contractor shall provide all plant, labour, equipment and materials necessary
for carrying out the tests.
Single and double packers of at least 500 mm length and capable of sealing
holes of any size between 76 and 59, both sizes inclusive, at a maximum
pressure of 120 bar down the hole, shall be available so that any section of a hole
can be tested at any stage of the drilling. The packers shall be pressurised with
liquids, not with air/gas, or of soft expandable rubber capable of sealing tightly
against the walls of the hole, particularly when the material is soft or friable to the
extent that enlargement of the hole is unavoidable.
600-TU-ETG-001
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4.3.3.6
Calibration Procedure
All flow meters, pressure gauges and the like shall be sealed and calibrated by an
approved laboratory before use on the site. The Contractor shall maintain on each site two
master pressure gauges calibrated and certified by an independent authority against which
working gauges shall be calibrated daily or before use. Any working gauge, which differs by
more than 5% from the master gauge, shall be removed from site. Arrangements shall be made
for the regular calibration of water flow meters. An adequate supply of spare parts shall be
maintained on site. At least one standby meter shall be available at all times.
At the start of work, the equipment to be used for the water pressure tests shall
be calibrated.
Alternative equipment, which reads the pressure in the test section directly, may
be used subject to Geners consent.
4.3.3.7
Programme of Work and Number and Position of Boreholes
Gener will set out the position of each borehole before drilling of the hole
commences. Gener will order the direction and inclination, and give an initial estimate of the
required length. The actual length required will be ordered while the hole is being drilled.
Gener may alter the programme of work as and when drilling results become
available.
4.3.3.8
Drilling
Workmanship and Setting-up

The Contractor shall ensure that his drilling machines are firmly anchored and do
not move while drilling is in progress.
Competent and experienced workmen shall perform all core drilling with
satisfactory workmanship. Special care shall be taken to obtain cores in as good
a condition as possible.
The Contractor shall withdraw the drill bit and remove the core as often as
necessary to ensure that the maximum possible amount of intact core is
recovered. He shall use bits of size suitable to the material to be cored and he
shall provide close surveillance of wash water, drilling pressure, lengths of runs
and all other factors significant to the nature of the material drilled.
Where necessary and as directed by Gener the Contractor shall use drilling fluid.
No greases, rod dope or other contaminants shall be used on any rods during
drilling operations.
600-TU-ETG-001
60
If unexpected cavities are encountered, drilling shall be suspended until further
drilling is authorised by Gener.
Tolerances
Holes for core drilling shall be located and drilled within the limits of accuracy set
out in Table 4-2.
Table 4-2:
Tolerances
Description
Alignment of drilling rig:
Permissible deviation from designated direction
Direction of hole:
Maximum deviation, % of drilled length
Depths shall be measured to the following
accuracies:
Depth of hole
Features in hole
Permissible Deviation / Degree of Accuracy

1
3%
0.01 m
0.01 m
Casing
Where drilling is being carried out in any stratum that is not sufficiently cohesive,
in the opinion of the Contractor, to stand firmly without a casing, or when directed
by Gener, that hole shall be cased.
Test Procedures
a)
Testing concurrent with drilling:

Only clear water, free of sediment, shall be used for these tests.
Water pressure tests shall be performed on sections of exploratory holes
drilled in rock, and shall generally be performed using a single packer on
sections of hole six (6) metres in length, unless otherwise ordered by
Gener. They shall be conducted after completion of the drilling of each
consecutive test length and in any event before the correction of caving.
The pressure gauge and flow meter must be coupled directly to the drill
rods in the hole so that no bends occur in the water line between the
pressure gauge and test section, but also so that pressure gauges and flow
meters can be easily read.
After drilling and prior to testing, the hole shall be flushed clean of drill
cuttings through the un-expanded packer for at least 5 minutes with clean
sediment free water until the return water is clear. The standing water level
shall then be measured and recorded after it has remained constant for 5
600-TU-ETG-001
61
minutes and just prior to expanding the packer and doing the test. The
water level shall again be measured and recorded immediately after the
packer is released at the end of the test.
Water shall be pumped into each test section at gauge pressures at the top
of the borehole of 3, 7, 10, 15 and 25 bar if not otherwise directed by
Gener.
Each stage of the test shall last at least 5 minutes. The acceptance of
water at each pressure shall be recorded at minute intervals for 5 minutes
or until a steady flow is attained. No pressure stage shall last more than 10
minutes. The required pressures shall be maintained to an accuracy of 5 %
during the whole of the period of each pressure stage.
If the water leaks past the packer and appears at surface, all efforts are to
be made to plug such leaks and report it in detail to Gener (location,
estimate of flow). If water leaks past the packer up the hole, Gener may
instruct the Contractor to abandon the test or move the packer to include
the section previously tested.
b)
Testing after completed drilling:

Specifications and test pressures as above except that testing is done in
stages of 5 m from the bottom up after the hole is drilled to final depth.
4.3.3.9
Handling and Storage of Core Samples
On removal of a core barrel from a hole and before the start of a new run the core
shall be carefully removed from the barrel using a steady pressure. If the core jams, gentle
tapping, using a rubber mallet, shall be used to free the core. Excessive hammering on the core
barrel resulting in damage to the core may cause the core and hence the hole to be rejected by
Gener. The core will be extracted over the core box, a ground sheet, or a sheet of clean
corrugated iron, to prevent loss and dirtying of dropped pieces.
The core will be placed in the correct sequence in the core box. The Contractor
will closely pack the core neatly in each row of the core box and will orient each piece against
the adjacent pieces so that all pieces have a common orientation. The orientation should
continue from run to run wherever possible.
The depth at the end of every run shall be marked on a square section white
painted block placed at the end of the run and on the core if it is hard enough. Core left behind
in the borehole at the end of the run will be marked as such at the top of the following run with a
line indicating where drilling started on the following run and an arrow from the top of the
following run to that line.
600-TU-ETG-001
62
Yellow painted square section blocks shall be placed in the correct position in the
core box to represent samples which have been taken from the hole. The markers shall be of
the same length as the samples they represent.
Where core is not recovered, red painted square cross-section blocks equal in
length to the lost core shall be placed in locations where core was lost. The minimum length of
core so marked shall be 10 mm. If core loss is distributed throughout the run, a single red
painted block, equivalent in length to the core loss and marked with a double ended arrow, shall
be placed before the block indicating the depth of the bottom or the run.
Were core does not fully fit a core box tray, it shall not be broken unless the
breaks are clearly marked with two indelible lines that cross the break. Any breaks introduced
by handling shall be marked in the same way. The core shall be left adjusted in the core box
trays and any space at the right hand end of the core box tray shall be filled with blue painted
square cross section blocks cut to fit the space and thus prevent the core from sliding about
during transport.
The borehole number, the completion date, the depth of the core, and the box
number (as, say box 1 of 5) shall be clearly, neatly and indelibly marked on both ends of the
box. In addition, the project name, client and data from box ends shall also be noted on the side
or inside top of the box.
No core box shall contain the cores of more than one hole. The depth or length of
core, as applicable, shall be given to the nearest centimetre.
4.3.3.10
Inclination and Orientation of Boreholes
Down-the-hole inclination and deviation surveys of some of the boreholes will be

ordered while the investigation is in progress. The instruments used shall be as stated in the
approved Core Drilling Equipment Data Sheet. The inclination and direction shall be determined
to within an accuracy of 0.5 and may be required to be recorded twice at each ordered survey
point within the borehole.
Measurement of core orientation will be required on certain holes or portions of
holes with use of Ezy-MarkTM Core Orientation system, or similar. Where so ordered, the
Contractor shall use the method as approved by Gener.
4.3.3.11
Backfilling
On completion of drilling and testing, after the consent of Gener, the boreholes
shall be backfilled with an approved cement grout mixture which shall be tremied or piped to the
bottom of the hole so as to displace any water that may remain in the hole until the grout is seen
to appear at the surface. The hole shall be topped up with grout as the tremie pipe is withdrawn.
600-TU-ETG-001
63
If Gener decides to keep a hole open after the demobilisation of a drilling site, the
Contractor has no responsibility for backfilling of the hole.
4.3.3.12
Record of Operations
The Contractor shall keep accurate records on approved forms as follows of all
drilling, sampling and grouting operations carried out.
Drilling Record :
Each drilling machine operator shall maintain independent of his own private
records, a record of all information required by Gener in a suitable book. This
book shall be kept up to date. It shall be available, at all times, for inspection by
Gener. On completion of the borehole, this book shall become the property of the
Employer. In the record book, a note must be made of:
a)
borehole number and co-ordinates, angle from vertical and direction,
b)
name of driller and type of machine,
c)
dates of setting up and removal,
d)
date of each advance,
e)
calculation of length for each advance/run,
f)
type and number of bit for each advance/run,
g)
bit pressure and rotational speed,
h)
times of start and finish of each advance/run, duration of any delays and
number of times chuck was raised if applicable,
i)
reasons for any core loss,
j)
location of any exceptionally hard or exceptionally soft layers,
k)
use of drill mud, type of drill mud,
l)
estimated water or drilling fluid losses or inflow, with location of

occurrences,
m)
amount and size of casing inserted into borehole,
n)
amount and size of casing drilled into borehole,
o)
amount and size of casing left in borehole,
p)
amount of cement grout poured or pumped into borehole,
q)
depth of top of grout after grouting operation,
r)
length of grout that required drilling,
s)
600-TU-ETG-001
64
time of and reason for delays e.g. mechanical, pumps, rods stuck etc,
t)
details and records of tests or surveys conducted,
u)
any other item that may be of relevance to the interpretation of the core or
the administration of the contract,
v)
determine depth at which changes of strata, fissures, seams, planes of

weakness in rock, changes in rock quality occur,
w)
geological description with Rock Quality Designation (RQD) and fracture

frequency,
x)
core recovery per run, and depth of each run.
Water Test Record :

Before commencing the water pressure test, the time of testing shall be recorded
on forms approved by Gener. During the testing, the details of time, gauge
pressure, water meter reading, water loss, leakage rate, sealing properties and
any other relevant information shall also be recorded on the test forms. On
completion of the test and after equipment is removed from the whole, the time of
completion shall be recorded, and the form shall be signed by the Contractors
representative who performed the test.
The Contractor shall provide a daily return of a summary of all drilling operations
on an approved form.
4.3.4
Services for Rock Mechanical Testing and Rock Stress Measurements
Testing and measurements will be done by professionals engaged and

co-ordinated by the Contractor and subjected to Gener's approval.
The Contractor shall in addition to drilling and water testing of boreholes provide:
Water and power necessary for execution of testing, including hydraulic
power unit capable of delivering a power of 25 kW at an oil pressure of 200
bar.
Core drilling machine with drill rods for inserting packers in drill holes
Personnel, vehicles, equipment, other machinery and materials as required
during testing.
Equipment for stress measurements in rock. The measurements shall be
performed according to Suggested Methods by ISRM.
4.3.5
Convergence Stations
Convergence anchors shall be min 0.5 m long, 20 mm diameter reinforcing bars

welded to a stainless steel head to suit the convergence tape used for measurement purposes.
600-TU-ETG-001
65
The convergence anchors shall be fully resin bonded into a drilled holed enlarged
at the surface to allow the head to be recessed.
Convergence stations shall generally be installed within 1 m of the excavation
front and the zero reading established before the front is advanced.
Readings shall be taken between all stations.
The convergence measurements shall be taken by means of a stainless steel
convergence tape. At least one spare convergence tape in excellent condition shall be available
at all times.
Readings shall be taken at the following frequencies:
after each blast, until the graph show the initial rapid linear convergence
phase has passed
thereafter at two blast intervals until the face has advanced to at least 20 m
thereafter at weekly intervals until the readings have stabilised
The convergence tape extensometer and compatible anchor points shall be as
supplied by the following or equivalent manufacturer:
ITM-Soil Interfels
DGSI Slope Indicator Co.
Borehole Extensometers
Borehole extensometers shall consist of multiple aluminium rods in protective
sleeves with groutable anchors, a reference head and protective cap. The rods shall be
recoverable for inspection and repair. The reference head shall be designed to allow fitting of
inductive displacement transducers into the bushings where remote readout is required. The
reference head shall be recessed to afford blast protection. The protective sleeve shall be made
according to the suppliers specification.
Extensometer stations will consist of multiple extensometers in the crown or walls
of underground excavations directed by Gener, and shall generally be installed within 1 m of the
face and the zero reading established before the face is advanced.
Reading frequencies shall be as for convergence stations.
Multiple point rod extensometers and compatible dial gauges or remote readout
facilities shall be obtained from approved suppliers.
600-TU-ETG-001
66
4.3.6
Piezometers
Electric piezometers shall consist of stainless steel housing, corrosion resistance

porous filter, membrane, vibrating wire type sensor and single reinforced connecting cable
without splicing.
Standpipe piezometers intended for long-term monitoring shall be equipped with
Casagrande piezometer tips or equivalent.
Boreholes for standpipe piezometer installations shall be drilled using rotary and
diamond drilling methods. Hollow stem augers with a minimum internal diameter of 83 mm may
be used for drilling overburden.
The backfill around the standpipe piezometer tip shall conform to the suppliers
specification. Two piezometer tips shall be installed within the same monitoring interval in each
hole. Backfill and Bentonite seal materials shall be installed in such a manner as to prevent
bridging or hanging up of the material within the borehole. Contractor shall provide a graduated
tape with a suitable weight attached in order to measure the depth. Contractor shall also supply
a water level indicator such as the RocTest CPR4.100f or equivalent.
The suppliers installation procedures shall generally be followed, but the
Contractor may modify these to take into account conditions encountered during the work.
If any piezometer is found to be ineffective due to deficiencies in the Contractors
installation procedures, the Contractor shall install a replacement piezometer.
Immediately upon completion of a piezometer installation, a protective casing,
complete with protective cap, shall be installed.
Piezometers and readout units shall be supplied by the following or equivalent:
Glotzl GmbH
Sick Maihak
RocTest Telemac
Geokon
4.3.7
Surface Settlement Monuments and Fixed Points
Monuments for precision triangulation instruments will be established. There will

be two types of monuments depending on the type of foundation; soil or rock.
The fixed points shall consist of a 25 mm brass rod, which shall be embedded in
concrete. The method of installation will depend on the foundation; concrete or soil.
600-TU-ETG-001
67
The establishment and positioning of the monuments and fixed points shall be as
directed by Gener.
Instruments may be established for monitoring movements of the monuments.
4.3.8
Joint Deformation Meters
Joint deformation meter shall consist of anchoring assembly, electrical sensor,

watertight shielded cables and digital readout equipment. Displacement will be measured in
only one direction but the instrument must allow movement of at least 25 % of the total range in
the direction not measured without damage to it.
Joint deformation meters shall be obtained from approved suppliers.
4.3.9
Ground Water Monitoring

Ground water monitoring and reporting shall be performed as requested by
Gener.
4.3.10
Materials
Multi-conductors used for connection of piezometers and extensometers shall be

according to the suppliers specification for permanent installations. Connections shall be
waterproofed.
Grout materials used for instrumentation purposes shall be approved by Gener.
4.3.11
Measuring Range
Measuring range of the instrument shall be as follows:
Remote-readout electric piezometers
0 to 500 kPa, 0 to 1 MPa and 0 to 2 MPa, depending

on location
Borehole extensometer
+ 200 mm without resetting
Joint meter
6, 12, 15 med mer
4.3.12
Accuracy and Resolution

Accuracy of the instrument shall be as follows:
Remote-readout electric piezometer
5 kPa
0.1 mm
Joint meter
0.05 %
600-TU-ETG-001
68
Resolution of the instrument shall be as follows:
Remote-readout electric piezometer
2.5 kPa
0.02 mm
Joint meter
0.01 %
5.
PAVEMENT IN WATER TUNNELS

Specifications.
All water tunnel floors shall be cleaned to top of rock and levelled with tunnel spoil
properly compacted. All soft material shall be removed and replaced by drainable material.
Where specified the tunnels shall be paved with concrete of minimum 150 mm as
shown in the Drawings. Concrete shall be Class H-30 (NCh170 Of85) with reinforcement mesh
min. 6.5 kg/m2 (deformed bars 420 N/mm2). Finishing of the surface shall be minimum Class
UB (N 600-CI-ETG-018). Contraction joints shall be placed for every 6 m distance transverse
to the tunnel axis. The joints may be sawed, which shall be done early enough to avoid
contraction cracks. The pavement shall have drain holes with minimum diameter 35 mm at a
distance of maximum 3 m.
Pavement in the access tunnel.
Final design of the pavement in the access tunnel, including drainage facilities
shall be carried out by the Contractor for Engineers approval.
Pavement of the access tunnels shall be according to applicable drawings.
Surface finish should be T2 (N 600-CI-ETG-018).

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PROYECTO HIDROELECTRICO ALTO MAIPO

GENERAL SPECIFICATIONS FOR TUNNELLING

Drilling of holes, exploratory drilling and grouting ................................................. 1

Classification and Definition ................................................................................. 1

Reference Standards ........................................................................................... 1

Submissions by the Contractor ............................................................................ 1

Test Reports ........................................................................................................ 2

Equipment and Execution .................................................................................... 3

Exploratory Drilling and Grouting ......................................................................... 3

Holes for other Purposes ..................................................................................... 4

Drilling Accuracy: ................................................................................................. 5

Deviation Measurements of Drill-holes ................................................................. 5

Water Pressure Tests .......................................................................................... 5

Flushing between holes ....................................................................................... 5

Logging of drill holes ............................................................................................ 7

Water Pressure Testing ....................................................................................... 8

Chemical grouts ................................................................................................. 10

Cement Grouting above ground ......................................................................... 10

Cement Grouting underground........................................................................... 11

Chemical Grouts ................................................................................................ 12

Scope and definitions ......................................................................................... 13

Classification and Definition ............................................................................... 13

Rock Mass Quality Classification ....................................................................... 14

Submittals by the Contractor .............................................................................. 14

Documents for submittal-Rock excavation ......................................................... 15

Test Reports ...................................................................................................... 15

Documents for submittal-TBM excavation .......................................................... 16

Rock Excavation ................................................................................................ 17

General Requirements ....................................................................................... 17

Illumination, Communication and Roadways ...................................................... 21

Open Cut Excavation ......................................................................................... 22

Drilling and Blasting (Above- and Underground) ................................................ 23

Excavation Tolerances ....................................................................................... 23

Drilling Accuracy ................................................................................................ 24

Smooth Blasting ................................................................................................. 24

Drilling and Reaming of Shafts by raise-boring machine (RBM) ......................... 25

Tunnel excavation by tunnel boring machine (TBM) ........................................... 25

Requirements to TBM machines ........................................................................ 26

Backup system .................................................................................................. 28

Invert concrete segments ................................................................................... 29

Assignment of risk during TBM excavation......................................................... 29

Utilisation of Materials ........................................................................................ 30

Rock Support ..................................................................................................... 30

Classification and Definition ............................................................................... 31

Rock Mass Quality Classification ....................................................................... 31

Rock Support Classification ............................................................................... 31

Reference Standards ......................................................................................... 33

Submissions by the Contractor .......................................................................... 33

Test Reports ...................................................................................................... 34

Inspection of Tunnels, Marking of Chainage, Wash-down .................................. 34

Rock Support ..................................................................................................... 35

Basic Scaling ..................................................................................................... 37

Additional Scaling .............................................................................................. 37

Rock Bolts and Accessories ............................................................................... 38

Drilling and Installation of Resin End-anchored Bolts ......................................... 40

Drilling and Installation of Fully Cement-grouted Bolts ....................................... 40

Measures to be taken in Case of Rejection and Re-bolting ................................ 42

Rock Anchors .................................................................................................... 43

Sprayed Concrete .............................................................................................. 44

Requirements for Sprayed concrete ................................................................... 46

Testing and Control............................................................................................ 47

Reinforcement of Sprayed Concrete .................................................................. 48