NEELUM-JHELUM HYDROELECTRIC PROJECT

PAKISTAN WATER& POWER DEVELOPMENT AUTHORITY

ENGINEERING SERVICES FOR

CONSTRUCTION SUPERVISION OF
NEELUM-JHELUM HYDROELECTRIC PROJECT

LOT C2 TBM
CONSTRUCTION REPORT

NEELUM JHELUMCONSULTANTS Tel: (+92) 58224 33653

Fax: (+92) 58224 32978
[JV between MWH, NORPLAN, NESPAK, ACE & NDC] e-mail: [email protected]

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ENGINEERING SERVICES FOR CONSTRUCTION SUPERVISION OF TBM CONSTRUCTION REPORT
NEELUM-JHELUM HYDROELECTRIC PROJECT

ENGINEERING SERVICES FOR

CONSTRUCTION SUPERVISION OF
NEELUM-JHELUM HYDROELECTRIC PROJECT

LOT C2 TBM
CONSTRUCTION REPORT
ENGINEERING SERVICES FOR CONSTRUCTION SUPERVISION OF TBM CONSTRUCTION REPORT
NEELUM-JHELUM HYDROELECTRIC PROJECT

TABLE OF CONTENTS

2.19. PERMANENT MATERIALS TESTING ................................................................................... 1

2.19.1. Introduction ................................................................................................................ 1
2.19.2. COARSE AGGREGATES ........................................................................................... 3
2.19.5. CEMENT/SLAG ......................................................................................................... 20
2.19.6. DEFORMED STEEL BAR/ROCK BOLT/WIRE MESH ............................................ 21
2.19.7. SOIL ........................................................................................................................... 24
2.19.8. ADMIXTURE.............................................................................................................. 25
2.19.9. GROUT ...................................................................................................................... 25
2.19.10. Conclusion and Recommendations ................................................................. 26
2.19.11. Lesson Learned .................................................................................................. 27

LIST OF FIGURES
ENGINEERING SERVICES FOR CONSTRUCTION SUPERVISION OF TBM CONSTRUCTION REPORT
NEELUM-JHELUM HYDROELECTRIC PROJECT

LIST OF TABLES
ENGINEERING SERVICES FOR CONSTRUCTION SUPERVISION OF TBM CONSTRUCTION REPORT
NEELUM-JHELUM HYDROELECTRIC PROJECT

2.19. PERMANENT MATERIALS TESTING

2.19.1. Introduction
The quality of permanent materials used in TBM mined tunnels were verified according to
American Society for Testing and Materials (ASTM), British Standards (B.S), American
Association of State Highway And Transportation officials (AASHTO) and Pakistan
Standards and Quality Control Authority (PSQCA) with special emphasis on latest edition of
above mentioned standards.

Any material procured for use in TBM mined tunnels were either tested at TBM site-C2 OR,
in case when no testing facility were available on this site the test sample dispatched to main
laboratory located in C-3 site for testing. There were some tests like sand stone petrographic
analysis and chemical analysis of some materials for which the subject samples were sent to
various governmental, semi-governmental or private testing agencies like Pakistan Council of
Scientific and Industrial Research (PCSIR), Wapda Central Material Testing Laboratory
(CMTL), Universities of Engineering and Technology located in Lahore, Peshawar and
Taxila. After getting the specified results proper approval was given by the Engineer for that
particular material. Concretes and shotcretes mix designs were prepared as per American
Concrete Institute (ACI) manuals. From start up to 14+009 RD of TBM S-696 and 13+900
RD of TBM S-697 a shotcrete mix design having designation C-35 having rough surface and
60:40 fine: coarse aggregate ratio was used to line the TBM mined tunnels, this mix was
originally approved for lining the tunnels mined by Drill and Blast method which were to be
overlaid by class C" concrete lining. This C-35 mix was consisting of 525 kilograms of
cement per cubic meter which were reduced to 500 kgs/Mᵌ and this mix was approved for
TBM use under the name C-35TBM.R1. As the TBM shotcretes were the final finished
surface and its surface was of importance and in order to control Manning N value four trials
i.e. C-35TBM.R3, C-35TBM.R4, C-35TBM.R5 and C-35TBM.R6 were conducted with
70:30, 80:20, 90:10, and 100% sand fine: coarse ratio. After assessment of trials data the
Designer asked us to conduct a trial with 75:25 fine: coarse ratio which, gave satisfactory
results and the Engineer gave approval for that mix with C-35TBM.R2 designation. This mix
was in use from 12+056 RD on TBM S-696 and 13+057 RD on TBM S-697 to 9+701 RD of
TBM S-696 and 9+516 RD of TBM S-697, But due to inconsistency in slump and long
haulage distance the contractor was advised to modify this mix to suit the job. The contractor
after changing the superplasticizer having retarding effect [RUIDI IX(B)]conducted a
successful trial and this mix was approved as C-35TBM.R7.

Class C-30 concrete was used in casting blocks for rail track sleepers.

During trials the unconfined compressive strength of plain shotcrete cylinders was tested as
per ASTM C-39.

The In-situ cores of plain shotcretewere tested as per ASTM C-42.

Steel fibers and plain Shotcrete rebound tests were conducted at tunnel face by collecting the
rebound material and calculating its percentages.

During trials steel fibers shotcretes cylinders were tested as per ASTM C-39.

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In-situ cores of steel fibers shotcretes were tested as per ASTM C-42.

Steel fibers used in shotcretes were tested to check its L/D ratio and tensile strength as per
ASTM A-820.

A dry shotcrete mix was designed and approved by the Engineer for spraying through Ocmer
spray machine on small patches and loose rock fragments in order to stabilize them.

Two shotcretes mix designs were approved for lining repairs at TBM tunnels named C-
35TBM .R8 which constitutes 100% fine aggregates and C-35TBM.R7 Ocmer, which is the
same mix as C-35TBM.R7 and the only difference is that this mix is sprayed through Ocmer
spray machine at construction joints or where small repairs were needed.

Aggregates both fine and course used in concretes, shotcretes were derived from local SS1
rocks by a 1000 T/day capacity crusher at C-2 site. The petrographic analysis and other
quality control tests were carried out by Dr. Nawaz advisor to chairman WAPDA for
construction materials and on his recommendations low alkali cements were used to control
alkali contents of concretes, shotcretes within 3.2 kgs/Mᵌ limits. During construction the
relevant ASTM and British standards were followed for quality control of aggregates.

Two brands of low alkali cements named Maple leaf cements and Fauji cements were used in
TBM tunnel lining shotcretes/concretes. ASTM standards C-150, C-191, C-109, and C-204
were followed for controlling the physical qualities of cements and for chemical qualities as
per ASTM C-114 cements were tested at TUSDEC which is a quality controlling agency for
cements, working under state cement corporation of Pakistan.

The quality of water used in construction of TBM tunnels were controlled through testing by
Water Quality Assurance Laboratory Muzaffar Abad AJK and National Institute of Health
Islam Abad who followed WHO, Pakistan Standards and Quality control Authority
guidelines.

To accelerate setting time of shotcrete an accelerator was used having brand name Meyco
(MasterRocK) SA-160 from BASF Company. ASTM C-1102 standard was followed for its
quality control.

Water reducing agent having brand name JG-2H was used in concretes/shotcretes, the testing
standard was ASTM C-494.

China made Nanjing RuidiX(B) a superplasticizer having retarding effects was used in
TBM shotcretes , the testing standard was ASTM C-494.

Air entraining agent named KF from china was used to incorporate and control air content in
concretes.

ASTM C-260 was followed to check the quality of KF.

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At the start of TBM tunnels wire mesh consisting of steel bars having 6.0mm Ø and aspect
ratio of 100*100 mm were installed up to RD15+659 of TBM-697 and RD 15+522 of TBM-
696 But to facilitate installation and shotcreting the aspect ratio was changed to 150*150mm
from RD 9+534 of TBM-697 and RD 9+918 of TBM-696. This 6.0mmØ wire mesh was spot
welded and ASTM-A82 was followed for quality control. At RD 9+918 of TBM-696
10.0mm Ø wire mesh was installed which was fabricated from deformed steel bars at C-2 site
by the contractor through manual welding process. ASTM-615 was followed to check the
quality of steel bars. In order to withstand the high overburden areas in TBM tunnels
convoluted wire mesh consisting of grade 60 plain steel bars having 10.0mm Ø were installed
in crown area from above chainages like RD 9+534 TBM-697 and RD 9+918 TBM-696.
Due to cut marks or grooves which resulted on bars peripheral area during fabrication it was
not possible to test this material through ASTM-615, a performance test was advised by TBM
Engineer like dropping a weight of 113 kgs from a height of 1.5 meters. Frequency of test
was 1500 pieces/Test.

Anchor shell or expansion shell rock bolts having brand name Sino rock (Chinese) and
Swellex rock bolts from Sweden were installed for tunnel support. Test standard followed
was ASTM-615 for tensile properties while galvanization thickness of these rock bolts and its
appurtenances was checked through a calibrated micrometer at C-2 and C-3 sites.

Micro silica from Chinese source (WU HU Yongpei) was used in some high strength
concretes and C-35TBM.R8 mix design applied on repair works of TBM tunnels. ASTM C-
1240 standard was followed to check micro silica properties.

Different mortars mix designs were approved for use in grouting of rock bolts. Originally
there was an approved mix design for mortar having designation M-45 which was used by
drill and blast section to grout solid rock bolts but this mix was not fit for grouting hollow
rock bolts so, this mix was redesigned by removing sand form it and was approved as M-45
G with 0.36 W/C ratio. Due to its loose marsh funnel viscosity this mix was revised and
approved under a name M-45Gr with 0.28 W/C ratio. This mix was used in grouting of
expansion shell and swellex rock bolts. Marsh funnel viscosity and density of mix was
checked and recorded at site while unconfined compressive strength and expansion was
checked and recorded in C-2 laboratory.
At the start of TBM tunnels UPNˢ from local origin were installed for immediate support
which were tested as per ASTM-A36 but in high overburden areas there was a need for
strong support so, TH-36 beams were installed in TBM tunnels which were later replaced by
TH-40 beams from Chinese source. Reference test standard were E-8 of ASTM

2.19.2. COARSE AGGREGATES

2.19.2.1.Sieve Analysis / Particle Size Distribution

Quality control testing of materials (Common test for C-2 site)

Name of material Coarse aggregates for concretes and shotcretes

Test names Sieve analysis/ Particle size distribution

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Reference standard ASTM C-136 and ACI 506-09

Size Frictions Tested 5~8mm for shotcrete, 5~19mm,19~38mm for concretes

Minimum Tests Required 2 Tests per week

Actual Tests carried out 2.67 tests per week

Variance + 795

Total number of tests/Test Passed 1273/1236

Tests Failed 37

2.19.2.2. Specific Gravity and Absorption

Quality control testing of materials (Common test for C-2 site)

Name of material Coarse aggregates for concretes and shotcretes

Test names Specific gravity and absorption test

Reference standard ASTM C-127

Minimum Tests Required 1 test fortnightly

Actual Tests carried out 2.58 tests fortnightly

Variance + 188.57

Total number of tests 308

Tests passed 308

Tests failed 0

2.19.2.3. Total Moisture Content of Aggregates by Drying

Quality control testing of materials (Common test for C-2 site)

Name of material Coarse aggregates for concretes and shotcretes

Test names Total moisture content of aggregates by drying

Reference standard ASTM C-566

Size Friction Used Sand, 5~8mm for shotcrete, 5~19mm,19~38mm for concretes

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Minimum Tests Required 1 Test daily

Actual Tests carried out 1.68tests daily

Variance + 1131 ( Test for every Individual size counted)

Total No; of tests/ Tests passed 2803/2803

Tests failed 0

2.19.2.4. Soundness Of Aggregates By Use Of Sodium Sulphate

Quality control testing of materials (Common test for C-2 site)

Name of material Coarse aggregates for concretes and shotcretes

Test names Soundness of aggregates by use of sodium sulphate

Reference standard ASTM C-88

Size friction used 5~8mm for shotcrete, 5~19mm,19~38mm for concretes

Minimum Tests Required 1 Test/Two months

Actual Tests carried out 1.47 tests/Two months

Variance + 13.13

Total No;of tests/ Tests passed 41/41

Tests failed 0

2.19.2.5. Los Angles Abrasion Test to Determine % Loss by Abrasion

Quality control testing of materials (Common test for C-2 site)

Name of material Coarse aggregates for concretes and shotcretes

Test names Loss Angeles abrasion test

Reference standard ASTM C-131

Size friction used 5~8mm for shotcrete, 5~19mm,19~38mm for concretes

Minimum Tests Required 1 test /two Months

Actual Tests carried out 1.69 tests/Two months

Variance + 19.13

Total number of tests /Tests passed 47/47

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Tests failed 0

2.19.2.6. Test for Clay Lumps and Friable Particles in Aggregates

Quality control testing of materials (Common test for C-2 site)

Name of material Coarse aggregates for concretes and shotcretes

Test names Test for clay lumps and friable particles in aggregates

Reference standard ASTM C-142

Minimum Tests Required 1 test fortnightly

Actual Tests carried out 1.7 tests fortnightly

Variance + 83.6

Total number of tests 203

Tests passed 200

Tests failed 3

2.19.2.7. Material Finer than 75 µm Sieve By Washing

Quality control testing of materials (Common test for C-2 site)

Name of material Coarse aggregates for concretes and shotcretes

Test names Testing aggregates to determine -75μm material

Reference standard ASTM C-117

Minimum Tests Required 1 test fortnightly

Actual Tests carried out 9.5 tests fortnightly

Variance + 1020.6

Total number of tests 1140

Tests passed 1131

Tests failed 9

2.19.2.8. Test for Determination of Particle Shape, Flakiness Index

Quality control testing of materials (Common test for C-2 site)

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Name of material Coarse aggregates for concretes and shotcretes

Test names Determination of particles shape and flakiness index

Reference standard BS-812

Size friction used 5~8mm for shotcrete, 5~19mm,19~38mm for concretes

Minimum Tests Required 1 test fortnightly

Actual Tests carried out 19.65 tests fortnightly ( Test for every Individual size counted)

Variance +2228

Total number of tests /Tests passed 2347/2343

Tests failed 4

2.19.2.9. Loose/Rodded unit wt

Quality control testing of materials (Common test for C-2 site)

Name of material Coarse aggregates for concretes and shotcretes

Test names Loose and rodded density of aggregates

Reference standard ASTM C-29

Size friction used 5~8mm for shotcrete, 5~19mm,19~38mm for concretes

Minimum Tests Required 1 test fortnightly

Actual Tests carried out 2.83 test fortnightly

Variance + 219

Total number of tests /Tests passed 338/338

Tests failed 0

2.19.3. FINE AGGREGATES (SAND)

2.19.3.1. Sieve Analysis / Particle Size Distribution

Quality control testing of materials (Common test for C-2 site)

Name of material Fine aggregates for concretes and shotcretes

Test names Sieves analysis

Reference standard ASTM C-136 and ACI 506-09

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Minimum Tests Required 1 Tests per week

Actual Tests carried out 1.7 test per week

Variance +167

Total number of tests 441

Tests passed 406

Tests failed 35

2.19.3.2. Specific Gravity and Absorption

Quality control testing of materials (Common test for C-2 site)

Name of material Fine aggregates for concretes and shotcretes

Test names Specific gravity and absorption test

Reference standard ASTM C-127

Minimum Tests Required 1 Test per fortnightly

Actual Tests carried out 1.37 test fortnightly

Variance +44.6

Total number of tests 164

Tests passed 164

Tests failed 0

2.19.3.3. Total Moisture Content of Aggregates by Drying

Quality control testing of materials (Common test for C-2 site)

Name of material Fine aggregates for concretes and shotcretes

Test names Total moisture content of aggregates by drying

Reference standard ASTM C-566

Minimum Tests Required 1 test daily

Actual Tests carried out 1.68 tests per day

Variance + 1131 ( Test for every Individual size counted)

Total number of tests 2803

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Tests passed 2795

Tests failed 8

2.19.3.4. Loose /Rodded Unit Weight

Quality control testing of materials (Common test for C-2 site)

Name of material Fine aggregates for concretes and shotcretes

Test names Loose and rodded density of aggregates

Reference standard ASTM C-29

Minimum Tests Required 1 test fortnightly

Actual Tests carried out 1.6 test fortnightly

Variance +71.6

Total number of tests 191

Tests passed 191

Tests failed 0

2.19.3.5. Soundness Of Aggregates By Use Of Sodium Sulphate

Quality control testing of materials (Common test for C-2 site)

Name of material Fine aggregates for concretes and shotcretes

Test names Soundness of aggregates by use of sodium sulphate

Reference standard ASTM C-88

Minimum Tests Required 1 test /four months

Actual Tests carried out 1.87 test /four months

Variance +12.1

Total number of tests 26

Tests passed 26

Tests failed 0

2.19.3.6. Sand Equivalent

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Quality control testing of materials (Common test for C-2 site)

Name of material Fine aggregates for concretes and shotcretes

Test names Sand Equivalent Test

Reference standard ASTM C-2419

Minimum Tests Required 1 Test fortnightly

Actual Tests carried out 1.19 tests fortnightly

Variance +22.6

Total number of tests 142

Tests passed 142

Tests failed 0

2.19.3.7. Material Finer than 75 µm Sieve By Washing

Quality control testing of materials (Common test for C-2 site)

Name of material Fine aggregates for concretes and shotcretes

Test names Testing aggregates to determine -75μm material

Reference standard ASTM C-117

Minimum Tests Required 2 Test per week

Actual Tests carried out 3.15 Test per week

Variance +274.3 ( Test for every Individual size counted)

Total number of tests 752

Tests passed 737

Tests failed 15

2.19.3.8. Organic Impurities

Quality control testing of materials (Common test for C-2 site)

Name of material Fine aggregates for concretes and shotcretes

Test names Testing of aggregates to determine organic impurities

Reference standard ASTM C-40

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Minimum Tests Required 1 test/ 2 Months

Actual Tests carried out 1.33 tests/ 2 Months

Variance + 9.13

Total number of tests 37

Tests passed 37

Tests failed 0

2.19.4. CONCRETE/SHOTCRETE
2.19.4.1. Plain shotcrete cylinders UCS (Invert)

Quality control testing of materials TBM S-696

Name of material Plain Shotcrete used in Invert concreting

Test names Unconfined compressive strength

Reference standard ASTM C-39

Minimum Tests Required 1 Test/100 M³ OR 1Test per Pour

Actual Tests carried out 1 Test/23.8 M³

Variance Nil

Total number of tests 76

Tests passed 76

Tests failed 0

Quality control testing of materials TBM S-697

Name of material Plain Shotcrete used in Invert concreting

Test names Unconfined compressive strength

Reference standard ASTM C-39

Minimum Tests Required 1 Test/100 M³ OR 1Test per Pour

Actual Tests carried out 1 Test/59 M³

Variance Nil

Total number of tests 54

Tests passed 54

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Tests failed 0

2.19.4.2. Steel fibers shotcrete cylinders UCS (Invert)

Quality control testing of materials TBM S-696

Name of material Steel fibersShotcrete used in Invert concreting

Test names Unconfined compressive strength

Reference standard ASTM C-39

Minimum Tests Required 1 Test/100 M³ OR 1Test per Pour

Actual Tests carried out 1 Test/100 M³

Variance Nil

Total number of tests 0

Tests passed 0

Tests failed 0

Quality control testing of materials TBM S-697

Name of material Steel fibers Shotcrete used in Invert concreting

Test names Unconfined compressive strength

Reference standard ASTM C-39

Minimum Tests Required 1 Test/100 M³ OR 1Test per Pour

Actual Tests carried out 1 Test/100 M³

Variance Nil

Total number of tests 0

Tests passed 0

Tests failed 0

2.19.4.3. Plain shotcrete panel cores UCS

Quality control testing of materials TBM S-696

Name of material Plain Shotcrete used on walls and crown

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Test names Unconfined compressive strength of panel cores

Reference standard ASTM C-42

Minimum Tests Required 1 Test/250 M³

Actual Tests carried out 1 Test/250 M³

Variance 1 Test/251 M³

Total number of tests 98

Tests passed 98

Tests failed 0

Quality control testing of materials TBM S-697

Name of material Plain Shotcrete used on walls and crown

Test names Unconfined compressive strength of panel cores

Reference standard ASTM C-42

Minimum Tests Required 1 Test/250 M³

Actual Tests carried out 1 Test/250 M³

Variance 1 Test/257 M³

Total number of tests 109

Tests passed 106

Tests failed 3

2.19.4.4. Steel fibers shotcrete panel cores UCS

Quality control testing of materials TBM S-696

Name of material Steel fibersShotcrete used on walls and crown

Test names Unconfined compressive strength of panel cores

Reference standard ASTM C-42

Minimum Tests Required 1 Test/250 M³

Actual Tests carried out 1 Test/250 M³

Variance 1 Test/211 M³

Total number of tests 237

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Tests passed 235

Tests failed 2

Quality control testing of materials TBM S-697

Name of material Steel fibersShotcrete used on walls and crown

Test names Unconfined compressive strength of panel cores

Reference standard ASTM C-42

Minimum Tests Required 1 Test/250 M³

Actual Tests carried out 1 Test/250 M³

Variance 1 Test/233 M³

Total number of tests 233

Tests passed 231

Tests failed 2

2.19.4.5. Dry shotcrete panel cores

Quality control testing of materials TBM S-696 and S-697

Name of material Dry Shotcrete (plain) used to fill cavities and cracks

Test names Unconfined compressive strength

Reference standard ASTM C-42

Minimum Tests Required 1 Test/250 M³

Actual Tests carried out 1 Test/250 M³

Variance Nil (this mix was applied only in temporary works)

Total number of tests 1

Tests passed 1

Tests failed 0

2.19.4.6. UCS of Concrete Rail Blocks

Quality control testing of materials TBM S-696 and S-697

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Name of material Concrete class C-30 for Rail track blocks

Test names Unconfined compressive strength

Reference standard ASTM C-39

Minimum Tests Required 1 Test/Month

Actual Tests carried out 1 Test/Month

Variance Nil

Total number of tests 53

Tests passed 52

Tests failed 1

2.19.4.7. Test for Fiber Content of Fresh Shotcrete

Quality control testing of materials TBM S-696

Name of material Steel fibers content

Test names Determination of fibers content in fresh shotcrete

Reference standard Vol;2A clause,6.9.4.2.5

Contract Document Volume 2A

Minimum Tests Required 1 Test/250 M³

Actual Tests carried out 1 Test/250 M³

Variance 1Test/260 M³

Total No; of tests/Tests passed 192/153

Tests failed 39

Quality control testing of materials TBM S-697

Name of material Steel fibers content

Test names Determination of fibers content in fresh shotcrete

Reference standard Vol;2A clause,6.9.4.2.5

Contract Document Volume 2A

Minimum Tests Required 1 Test/250 M³

Actual Tests carried out 1 Test/250 M³

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Variance 1 Test/251 M³

Total No; of tests/Tests passed 217/176

Tests failed 41

2.19.4.8. Compressive Strength In situ Cores

Quality control testing of materials TBM S-696

Name of material Shotcrete used on walls and crown

Test names Unconfined compressive strength of In-situ cores

Reference standard ASTM C-42

Dimensions of cores ø50mm, Height 100mm

Minimum Tests Required 1 Test/250 M

Actual Tests carried out 1 Test/250 M³

Variance PO # 13690

Total No; of tests/Tests passed 20/19

Tests failed 1

Quality control testing of materials TBM S-697

Name of material Shotcrete used on walls and crown

Test names Unconfined compressive strength of In-situ cores

Reference standard ASTM C-42

Minimum Tests Required 1 Test/250 M³

Actual Tests carried out 1 Test/250 M³

Variance PO # 13690

Dimensions of cores ø50mm, Height 100mm

Total No; of tests/Tests passed 80/72

Tests failed 8

2.19.4.9. Shotcrete Rebound Test

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Quality control testing of materials TBM S-697

Name of material Shotcrete

Test names Shotcrete rebound test

Reference standard Contaract document Vol;2A

Contract Clause 6.12.5

Minimum Tests Required As required by Engineer

Actual Tests carried out 5

Variance As required by Engineer

Total number of tests /Tests passed 5

Tests failed 0

Quality control testing of materials TBM S-696

Name of material Shotcrete

Test names Shotcrete rebound test

Reference standard Contaract document Vol;2A

Contract Clause 6.12.5

Minimum Tests Required As required by Engineer

Actual Tests carried out 2

Variance As required by Engineer

Total number of tests /Tests passed 2

Tests failed 0

2.19.4.10. Flexural Toughness Of Shotcrete Beam

Quality control testing of materials TBM S-696

Name of material Shotcrete sprayed to line TBM mined tunnels

Test names Flexural Toughness

Reference standard ASTM C-1018

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Dimensions of beam 100mm*100 mm*400mm

Minimum Tests Required 1 Test/1000 M³

Actual Tests carried out 1 Test/1000 M³

Variance 1 Test/757 M³

Total No: of tests/Tests passed 66/66

Tests failed 0

Quality control testing of materials TBM S-697

Name of material Shotcrete sprayed to line TBM mined tunnels

Test names Flexural Toughness

Reference standard ASTM C-1018

Dimensions of beam 100mm*100 mm*400mm

Minimum Tests Required 1 Test/1000 M³

Actual Tests carried out 1 Test/1000 M³

Variance 1 Test/735 M³

Total No: of tests/Tests passed 74/74

Tests failed 0

2.19.4.11. Concrete /Shotcrete Mix Design

Quality control testing of materials (Common test for TBM S-696 and S-697)

Name of material Shotcretes and concretes

Test names Mix designs

Reference standard ACI-506 and ACI 211

Minimum Tests Required One trial for any change in mix ingredients

Actual Tests carried out One trial for any change in mix ingredients

Variance Nil

Total number of tests 19

Tests passed 18

Tests failed 1

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2.19.4.12. Water Tests

Quality control testing of materials (Common test for C2)

Name of material Water

Test names Chemical and physical analysis of water

Reference standard W.H.O and Pakistan Standard

Minimum Tests Required 1 test/4 months

Actual Tests carried out 16

Variance +4

Tests passed 16

Tests failed 0

2.19.4.13. Concrete for TBM Tunnel Lining

Quality control testing of materials TBM S-696

Name of material Concrete class C-30 for TBM Tunnel LINING

Test names Unconfined compressive strength

Reference standard ASTM C-39

Minimum Tests Required 1 Test/100 M³

Actual Tests carried out 1 Test/100 M³

Variance Nil

Total number of tests 29

Tests passed 29

Tests failed 0

Quality control testing of materials TBM S-697

Name of material Concrete class C-30 for TBM Tunnel LINING

Test names Unconfined compressive strength

Reference standard ASTM C-39

Minimum Tests Required 1 Test/100 M³

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Actual Tests carried out 1 Test/88 M³

Variance Nil

Total number of tests 47

Tests passed 47

Tests failed 0

2.19.5. CEMENT/SLAG

2.19.5.1. Cements and slags physical testing

Quality control testing of materials (Common test for C-2 site)

Name of material Cement and Slag

Test names Specific surface, Fineness, consistency, setting time, soundness, UCS

Reference standard ASTM C-150,C-191,C-109,C-204

Minimum Tests Required 1 Test/consignment

Actual Tests carried out 1 Test/consignment

Variance Nil

Total number of tests 587

Tests passed 569

Tests failed 18

2.19.5.2. Micro silica

Quality control testing of materials (Common test for C-2 site)

Name of material Silica Fumes

Test names SiO2 content, moisture content, loss on ignition, strength activity test

Reference standard ASTM C-1240

Minimum Tests Required 1 Test/consignment

Actual Tests carried out 1 Test/consignment

Variance Nil

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Total number of tests 17

Tests passed 16

Tests failed 01

2.19.6. DEFORMED STEEL BAR/ROCK BOLT/WIRE

MESH
2.19.6.1. Steel Bars physical testing

Quality control testing of materials (Common test for C-2 site)

Name of material Steel Bars

Test names Tensile strength, Bend, elongation, unit weight, deformation

Reference standard ASTM A-615

Minimum Tests Required 1 Test/Heat number

Actual Tests carried out 1 Test/Heat number

Variance Nil

Total number of tests 874

Tests passed 841

Tests failed 33

2.19.6.2. Pull Out Test for Acceptance

Quality control testing of materials for TBM S-696

Name of material Expansion Shell rock bolts

Test names Pull-out test

Reference standard ASTM D-4435

Minimum Tests Required 5 % of total installed L1 59030,L2 6567

Actual Tests carried out

Variance ???

Total number of tests 6

Tests passed 6

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Tests failed 0

Quality control testing of materials for TBM S-697

Name of material Expansion Shell rock bolts

Test names Pull-out test

Reference standard ASTM D-4435

Minimum Tests Required 5 % of total installed L1 57226,L2 1336

Actual Tests carried out

Variance ???

Total number of tests 14

Tests passed 14

Tests failed 0

2.19.6.3. Wire mesh -6mm

Quality control testing of materials TBM S-696 and S-697

Name of material ø6mm Wire mesh

Test names Tensile strength, Bend, Elongation, Unit weight, Aspect ratio

Reference standard ASTM A-82

Minimum Tests Required 1 Test/consignment(1000 pieces Max)

Actual Tests carried out 1 Test/consignment(1000 pieces Max)

Variance Nil

Total number of tests 43

Tests passed 41

Tests failed 2

2.19.6.4. Wire mesh -8mm

Quality control testing of materials TBM S-696 and S-697

Name of material ø8mm Wire mesh

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Test names Tensile strength, Bend, Elongation, Unit weight, Aspect ratio

Reference standard ASTM A-82

Minimum Tests Required 1 Test/consignment(1000 pieces Max)

Actual Tests carried out 1 Test/consignment(1000 pieces Max)

Variance Nil

Total number of tests 19

Tests passed 19

Tests failed 0

2.19.6.5. Wire mesh -10mm convoluted

Quality control testing of materials for TBM S-696 and S-697

Name of material ø10mm convoluted Wire mesh

Test names Weight drop test (H-1.5M,weight 113kgs)

Reference standard Site Performance Test

Minimum Tests Required 1 Test/consignment(1500 pieces Max)

Actual Tests carried out 1 Test/consignment(1500 pieces Max)

Variance Nil

Total number of tests 132

Tests passed 132

Tests failed 0

2.19.6.6. Swellex rock bolts

No test carried out.

2.19.6.7. TH-36

Quality control testing of materials for TBM S-696 and S-697

Name of material TH-36 Beams

Test names Tensile strength, Yield strength, Elongation

Reference standard ASTM E-8

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Minimum Tests Required 1 Test/consignment

Actual Tests carried out 1 Test/1000 sets

Variance 2413 sets

Total number of tests -2

Tests passed 1

Tests failed 0

2.19.6.8. TH-40

Quality control testing of materials for TBM S-696 and S-697

Name of material TH-40 Beams

Test names Tensile strength, Yield strength, Elongation

Reference standard ASTM E-8

Minimum Tests Required 1 Test/consignment

Actual Tests carried out 1 Test/1000 sets

Variance Nil

Total number of tests 5

Tests passed 5

Tests failed 0

2.19.6.9. UPN
No test carried out.

2.19.7. SOIL
2.19.7.1. Particle Size Distribution

Quality control testing of materials TBM S-696 and S-697

Name of material TBM Muck material

Test names Grain size analysis

Reference standard ASTM D-2216

Minimum Tests Required As per site instructions

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Actual Tests carried out As per site instructions

Variance Nil

Total number of tests 14

Tests passed N/A

Tests failed N/A

2.19.7.2. Moisture Content

No test carried out.

2.19.7.3. Field Density Test (Water Replacement)

No test carried out.

2.19.8. ADMIXTURE
2.19.8.1. Physical Testing

Quality control testing of materials (Common test for C-2 site)

Name of material Admixtures (super plasticizers, Accelerator, (Air ent; agent)

Test names Setting time, Solid content, PH value, Density, Sp.g

Reference standard ASTM C-1102, C-494

Minimum Tests Required 1/Batch number

Actual Tests carried out 1/Batch number

Variance Nil

Total number of tests 560

Tests passed 551

Tests failed 09

2.19.8.2. Chemical Testing

Same as 2.19.8.1.

2.19.9. GROUT
2.19.9.1. Density-UCS of cubes-Expansion

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Quality control testing of materials for TBM S-696

Name of material Grouts

Test names Density, Compressive strength UCS, Expansion

Reference standard ASTM C-109, C-942

Minimum Tests Required One Test per check request

Actual Tests carried out 9

Variance 3 tests/year or as directed by the Engineer

Total number of tests 9

Tests passed 9

Tests failed 0

Quality control testing of materials for TBM S-697

Name of material Grouts

Test names Density, Compressive strength UCS, Expansion

Reference standard ASTM C-109, C-942

Minimum Tests Required One Test per check request

Actual Tests carried out 9

Variance 3 tests/year or as directed by the Engineer

Total number of tests 9

Tests passed 9

Tests failed 0

2.19.10. Conclusion and Recommendations

All materials supplied to TBMˢ were properly sampled, tested and after qualifying the
reference standard, it was approved by the Engineer for use on site.

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The co-ordination need to be improved between the contractor’s quality section and higher
management to minimize wastage of time among submission of request to Engineer,
collecting of sample from material and acquiring of test results if sample is tested at off-site
testing agency or in Main laboratory at C-3. Any recommendations by the Engineer need to
be addressed without wasting time as the contractor’s hesitation to switch from one material
to another and lack of much needed co-ordination between its different sections has caused
wastage of time.
Due to urgency of work, any material need to be sampled, tested and got approved keeping in
view the same degree of urgency, as the project is requiring. Any message which is of
importance be conveyed to the contractor’s responsible person who is able to take prudent
decision as in most of occasions the lower staff can not realize the exact degree of
requirement. Written instruction be preferred rather than verbal ones as there communication
problem between the contractor and consultant.

2.19.11. Lesson Learned

At NJHP CGGC the main contractor has hired laboratory staff from a Chinese commercial
laboratory who has no influence or control on issues relating to construction materials. Here
at C-2 site the laboratory manager of contractor cannot take any decision unless he informs
the Forman in-charge of work area 3 who after conveying message to higher authorities takes
the decision.

For any decision relating to materials the laboratory manager be given the authority in the
absence of which even small issues go to higher authorities of contractor which could be
solved in short time.
The consultant supervisory staff rather than discussing small problems with laboratory
manager are giving consultation to Chinese Foreman of work area 3 who has no knowledge
about materials and whose objective is only production not the quality.

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