Specialist

Grouting

GROUTING SOLUTIONS
Keller Ground Engineering has

K E L L E R M E E T S YO U R E N G I N E E R I N G N E E D S

sixty years grouting experience.

Whether a common application

or one that draws upon our

APPLICATIONS

unparalleled experience and

G
ROUND MODIFICATION SOLUTIONS
SOILFRAC

SOILCRETE PERMEATION COMPACTION

INFILL

Ground Water Control

creativity throughout Australia,

Underpinning

New Zealand and the South

Settlement Control

Pacific we assist engineers,

contractors and owners with

Ground Strengthening/
Consolidation

identifying and implementing

Settlement Reversal

the right solution from outline

Void Grouting

concept to detailed design and

Dam Grouting

execution for any situation.

Excavation Support
Leachate Control
Mine & Shaft Infilling

Pile Base & Shaft Grouting

Piping Failure Control
Sealing Slabs
Solution Features
Swallow Holes
Shaft Bases

LIMITS FOR GROUTING TECHNIQUES:

Clay

Silt

Sand

Gravel

Cobbles

Tunnelling Support

100

Underslab Grouting
Liquefaction Prevention

Soilcrete - Jet Grouting

80

Synthetic Solutions
Sodium Silicate
Solutions [lv]
Compaction Grouting

Foundation Support

40

General Cement
Soil Frac

20
optimal

0,002
can be used in exceptional circumstances

0,006
0,02
0,06
Grain size [mm]

0,2

0,6

2,0

6,0

20

60

Passing by weight [%]

60

Micro fine Cement

less optimal

Ground Compaction

SOILCRETE JET GROUTING

SOILCRETE JET GROUTING

THE PROCESS

CONSTRUCTION SEQUENCE

Jet Grouting is a Ground Modification System used to create insitu, cemented formations
of soil. Using high velocity (>100m/s) cutting jets of water or cement suspension (grout) the
system erodes and insitu mixes the soil to form the soil grout composite material.

Soilcrete Jet Grouting equipment consists of a high pressure pumping unit, cement mixing
equipment, storage silo and stores containers.

Soilcrete Jet Grouting can be carried out using three different systems. The choice of method is determined by the
soil conditions, the required geometry, the required Soilcrete parameters and the application.
Backflow

Grout

Backflow

Air
Grout

Backflow

Air
Water
Grout

Air shrouded
grout jet

Grout jet

Air shrouded
grout jet
Air

Grout jet

Single System:

Double System:

Triple System:

Single System operates with

a grout jet for simultaneous
cutting and mixing of the
soil. The Single System is
used for small to medium
sized Soilcrete columns in
low density soils.

The Double System uses a

compressed air shroud around
the jet nozzle to increase the
erosion capability of the jet.
The Double System is used
in dense soils, installing panel
walls, underpinning and mass
treatment.

Typically used for underpinning

and in sensitive or highly
variable soils, the Triple
system erodes the soil with
an air shrouded water jet and
simultaneously injects grout
into the eroded soil through
an additional nozzle.

SUPER JET
Keller Ground Engineering hold the
exclusive licence for the Super Jet system.
Developed in Japan and operated by Keller
companies in North America, Europe and
the Pacific, Super Jet takes advantage of
tool efficiencies and increased energy to
deliver columns up to 5.0m in diameter.
The benefits of Super Jet are technical
supremacy, reduced program periods and
costs.

Excavated 5.0m Super Jet Column.

100

The permeability and strength of the Soilcrete can be

controlled by the addition of additives to the grout mix.

50

UCS (MPa)

<5

<10

<20

Super Jet monitor and nozzle.

Compressive strength in % of the final strength

non-cohesive
soil

75

Mixer/
pump

1. Drilling

2. Grouting

3. Continuation

Drill rods fitted with jet

nozzles are bored to the final
depth using grout to stabilize
the hole. Jetting commences
at the base of the hole.

Turbulence caused by the jet

results in the uniform mixing
of grout and soil. Excess
water, soil and grout returns
to the surface through the
space between the drill rod
and borehole wall.

Additional columns can be

added fresh on fresh or fresh
on firm. Sequence depends
upon the jetting system
as well as the technical
requirements of the structure
being treated.

cohesive soil

For retaining structures design checks are made for the

competency of the soils below the base for bearing
and settlement together with an evaluation of the
internal shear and bending stresses in the Soilcrete.
The strength of the Soilcrete is a function of the insitu
soils and strength variations are to be expected, for this
reason a factor of safety of 2.5 to 3.0 is typically applied
for an average allowable strength.
The size of the Soilcrete mass to be created is dictated
by the application, a variety of geometries can be achieved.
The width or diameter of each panel or column is
determined during the design stage. Reliable descriptions
of the soil composition and strength or density allows
this assessment to be made with confidence.

25
0

14

21

28

42

Setting time [days]

Development of Soilcrete Strength with time

Cement/
Bentonite

Soilcrete Jet Grouting can be designed to mix or almost fully replace a soil with grout. For the
common application of underpinning, excavation support and groundwater cut-off the design
consists of developing a continuous Soilcrete mass to resist over turning and sliding whilst
maintaining the integrity of supported structures or utilities.

The compressive strength of Soilcrete is a

function of the cement content of the grout
and grading of the portion of soil within the
Soilcrete mass.

Gravel

Water

D E S I G N A N D Q UA L I T Y C O N T R O L

T H E P R O P E RT I E S

Type of Soil Silt or Clay Sand

The grout mixing and pumping unit is connected to the drill rig with high pressure hoses and control cables allowing
remote location of the plant. The jetting process can be performed using a wide range of drilling rigs with mast heights
varying from 2.5m to 35.0m. The boreholes are normally contained in shallow trenches used to direct the flow of the
excess soil-water-cement spoil to tanks or settling ponds.

Left: Soilcrete underpinned Heritage Building, Manly NSW

Top: Intimate bond between Soilcrete and Foundation.
Middle: Double or Triple Rods provide separate flows of grout, air and water.
Bottom: Jet grout pump.

SOILCRETE JET GROUTING

SOILCRETE JET GROUTING

D E S I G N A N D Q UA L I T Y C O N T R O L

A P P L I C AT I O N S
In contrast to conventional grouting Soilcrete Jet Grouting may be used for stabilization and
sealing of all kinds of soil ranging from loose granular sediments to clay. This applies for
homogenous soil formations and variable soil layers. Weak rock formations have also been
treated with Soilcrete Jet Grouting.

POSL
Ps

Pw
c

Pps

(W + WSC) a + Pps b
> 1.5
(Ps c) + (Pw d) + (POSL e)

FS sliding =

Pps + F
> 1.5
Ps + Pw + POSL

Moment arms
Base soil adhesion
Base soil friction angle
Friction force
Factor of safety
At-rest or active soil force

Full Column
Half Column
Partial Column

Legend
a,b,c,d,e
Ca

F
FS
Ps

Posl
Pps
Pw
W
WSC
WSL

Surcharge force
Passive force
Hydraulic force
Weight of structure footing load
Weight of Soilcrete
Surcharge load

Critical aspects of a successful Soilcrete jet grouting program are quality assurance and
quality control. These ensure that sub-surface soils are consistent with design assumptions
and that design parameters are met or exceeded.
Typically projects commence with a test section to verify
the design geometry and to confirm the quality and strength
characteristics of the Soilcrete material. During the Jet
Grouting process a series of inspection items are monitored
and documented, these include:
Drilling:

Location, angle, depth;

Batching:

Preparation of grout for

consistency in material content and
physical and chemical properties;

Jetting:

Checking of drill parameters (lift

speed, rotation rate) and injection
parameters (pressure and flow of
all inputs);

Sampling & Testing: Retrieval of representative

samples for external testing.

Right: SuperJet Grouting to provide tunnel support

at RNA Showgrounds, Brisbane

Foundation
Restoration

Column Walls

Historic buildings may be

endangered in the event of
settlements occurring. Soilcrete
provides a safe foundation with the
maximum structural protection.

In the event of higher mechanical

strain by shear force, danger
of undermining or of a high
impermeability requirements, cut
off walls of intersecting Soilcrete
columns may be constructed.

Double Panel Wall

Q UA L I T Y A S S U R A N C E

Construction times and

correlation to any sampling;

Soilcrete panel walls to cut off

ground water are used below
roads and buildings, for crossing
pipelines and to subdivide building
pits into different excavation
sections. According to the sealing
requirements single or multiple
panels may be constructed.

Single Panel Wall

Sheet Pile
Sealing Systems

Documentation:

Panel Walls

Underpinning by means of
low deformation gravity walls,
sometimes also used as a ground
water seepage barrier, may be safely
constructed even from confined
working areas. Can be used in
conjunction with ground anchors.

SOILCRETE GEOMETRICS

*
F = (W + WSC) tan + w Ca
FS overturning* =

Underpinning

Foundation
Improvement
Changes in use or modifications
of buildings often require an
enlargement or alternation of
the foundation. Soilcrete is an
economical and flexible solution
for this task.

Joint Sealing
For sealing of joints between piles,
sheet piles or other construction
parts in the ground, Soilcrete
is ideal.

Shaft Supports

Dam Sealing

Shafts with intersecting Soilcrete

columns are constructed if a
vibration free installation is required
and/or the shafts enter into ground
water bearing strata.

Soilcrete may be used to repair

dam cores or enlarge cut-off walls
in or below dams.

Earth Pressure
Relief

Sealing Slabs

Structures exposed to earth

pressures, such as historical walls,
abutments, steep slopes protections
or quay walls may be relieved by
the addition of or connection to a
backup Soilcrete body.

Soilcrete sealing slabs are

constructed by means of
overlapping columns within an uplift
proof depth. The sealing slabs may
be connected to any kind of vertical
sealing systems.

Top: Self Drilling jet grout monitor

Middle: Drill head and mast
configuration
Bottom: Joint sealing between piles

COMPACTION GROUTING

COMPACTION GROUTING

THE PROCESS

CONSTRUCTION SEQUENCE

When compaction grout is injected into loose soils, homogeneous grout bulbs are formed that
displace, densify and thus strengthen the surrounding soil. Originally developed as a remedial measure
for building settlement control the technique has evolved to treat a wide range of sub-surface
conditions including rubble and poorly placed fill, loosened or collapsible soils, sinkholes and
liquefiable soils.

Competent Backfill

Competent Backfill

Competent Backfill

Loose Stratum

Loose Stratum

Loose Stratum

Firm to Medium Stratum

Firm to Medium Stratum

Firm to Medium Stratum

Installation Of Grout Pipe:

Drill or Drive Casing
Record Ground Information
from Casing Installation

Initiation of Grouting:
Typically a bottom up process
Grout quality important
Slow uniform stage injection

The grout mix must have specific characteristics;

a very low mobility (low slump) mixture that is
pumpable but upon installation, exhibits an internal
friction enabling it to remain intact and displace the
surrounding soil without fracturing it
Compaction grout improves ground conditions by
displacement of soil particles.

Continuation of Grouting:
On-site batching of grout can
aid control
Sequencing of plan injection
points very important
Usually injection is pressure or
volume limited

A D VA N TA G E S O F C O M PA C T I O N G R O U T I N G

Can be performed in very restricted access

No need to connect to existing foundations
Economic alternative to removal & replacement or piling
Volume and pressure control options

Pinpoint treatment
Speed of Installation
Non Hazardous
No waste disposal
A high viscosity (low mobility) aggregate grout is
pumped into the ground in stages to displace and
densify the surrounding soils. By sequencing the grout
injections from primary to secondary and tertiary
locations this densification process can be performed
to achieve the required improvement.

Tip Resistance (MPa)

0

10

20

30

40

Above: Low mobility compaction grout.

Left: Controlled underpinning of shallow foundations.

DESIGN
A number of aspects must be considered for compaction grouting to
work best:

The insitu vertical stress in the treatment zone must be sufficient to enable the
grout to displace horizontally and hence avoid uncontrolled heave.
In saturated soils a pore water pressure increase will occur as a result of
ground displacement, for effective densification this must dissipate.
Soils that loose strength during remolding should be avoided
Greater displacement will occur in weaker soil strata, exhumed grout bulbs confirm
that compaction grouting focuses improvement where it is needed most.

Quality control includes procedural inspection and documentation of

work activity, testing to ensure proper mix design and verification works.

Left: Cone Penetrometer Test results, such as the ones illustrated left for volume
cut-off and pressure cut-off, show the degree of improvement achieved by
compaction grouting.
Right Top: Grout tubes
Right Centre: Steel point on driving shoe
Right Bottom: Driving grout pipes

PERMEATION GROUTING
THE PROCESS

THE PROCESS

Permeation Grouting is the injection of a fluid grout into granular,

fissured or fractured ground to produce a solidified mass to support
increased load and/or to fill voids and fissures to control water flow.

Rock Grouting is normally performed in fissured rock masses to reduce

the flow of water along the joints and discontinuities in the rock.

Grout Materials include:

General Cement
Micro-fine Cement
Sodium Silicate Solutions

Cement Grouts are often applied with admixtures or additives to improve grout stability,
viscosity or durability. Common Admixtures include: bentonite, sand, plasticiser and PFA.

DESIGN

Permeation of cement or chemical

grout through granular soil.

ROCK GROUTING

Dependent upon the preferred grout viscosity and particle size.

Generally limited to soils containing sand and gravel size particles only.

CONSTRUCTION SEQUENCE
Grout can be injected into the soil by a variety of methods:

Hand Driven lances or spears.

Drilled casings with grout injected through the end of the hollow casing.
Tube--manchette (TAM), a series of pipes with regular spaces rubber sleeve
covered injection holes.

D E S I G N A N D Q UA L I T Y C O N T R O L

Soilfrac Compensation Grouting is a process used to control or

reverse the settlement of structures. It uses similar equipment
and grout materials as permeation grouting to induce fractures in
the soil thereby causing an expansion to take place counteracting
settlement and producing controlled heave of the foundation.
The system can be applied in all soil types.

CONSTRUCTION SEQUENCE
Soilfrac is an observational process involving the installation of grout injection tubes
(TAM) in a pre-determined pattern, careful injection of grout through sleeves to
fracture the soil and the monitoring of ground or building movements to feed back into
the grouting regime.

A D VA N TA G E S O F S O I L F R A C
C O M P E N S AT I O N G R O U T I N G

Method is usually performed from outside the building without disruption.

Repeatable process allows settlement to be controlled on an ongoing basis.
Cost effective.

Pile wall

10

Soilfrac grouting
to limit settlement
due to deflection

Top: Grout fractures emanating from TAM pipe in clay

Middle: TAM pipe and Soilfrac injection
Bottom: Typical application to mitigate potential for settlement damage due to
adjacent piling and excavation.

Injection pressure and volume is recorded during the injection.

Periodic water testing (lugeon test) is performed to demonstrate the
achieved reduction in permeability.

Electronic monitoring and recording of grout injections can be used to provide

significant cost savings through ongoing observational design of the grouting.

CONSTRUCTION SEQUENCE

SOILFRAC COMPENSATION GROUTING

THE PROCESS

Grout is typically injected in isolated stages from boreholes drilled using

rotary percussive drills.
Reduction in permeability is a function of the grouting material, the rock and
grout design.
Rock Grouting is typically performed with General Purpose, Ultra-fine or
Micro-fine Cements.

Drill and Grouting is progressed in either Down stage or Up Stage

manner.
Grout viscosity varied during each stage injection to ensure effective grout
penetration.
Holes are drill and grouted in a split spacing method with a primary,
secondary, tertiary, etc approach.

Rock grouting in Hawkesbury

sandstone, Sydney NSW.

MINE INFILL GROUTING

THE PROCESS
Coal and mineral extraction has taken place for the past two centuries
using a variety of methods. With exhausted workings in various states
of collapse careful consideration needs to be given to the most
appropriate method of treatment.

Consolidation and Void fill grouting is the

preferred method when access to the seam
is not possible.

CONSTRUCTION SEQUENCE

A perimeter barrier is installed to prevent

grout migration
Grout is pumped through tremmie pipes
placed in pre-drilled holes.
Temporary casing is used to support the drill
hole in unstable ground

DESIGN & QUALITY CONTROL

Keller Ground Engineering offer a full

remediation design and construct service to
meet all the needs of the project.
Works performed in accordance with
established practice developed from extensive
international experience of similar projects.

Perimeter Borehole
Infill Boreholes

Infill Boreholes

Superficial Deposits

Coal Measures Strata

Worked Coal Seam

Pillar left in workings

Infill Grouting by
Tremmie Pipe

Gravel Barrier at Perimeter

11

Ke l l e r
G ro u n d
E n g i n e e ri n g
Pty Ltd
BRISBANE
MELBOURNE
SYDNEY
PERTH
Enquiries to:
PO Box 7974, Baulkham Hills NSW 1755
Level 1, 4 Burbank Place
Baulkham Hills NSW 2153 Australia
t: (02) 8866 1155
f: (02) 8866 1151
e: [email protected]
w: www.kellerge.com.au

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