MS Grout Rev A

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Type: Scale: Folio: Pages:
BLACK A4 2/39
WORK PROCEDURE FOR
Rubric Group Issuer Lot Ref Number Ind.
GROUTED BASE PLUGS
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LIST OF CONTENT
1 SCOPE ..................................................................................................................................................... 4
2 REFERENCE DOCUMENTS ................................................................................................................... 4
2.1 Contractual Documents.................................................................................................................... 4
2.2 Works Documents for Each Box ...................................................................................................... 4
3 GENERAL ................................................................................................................................................ 4
4 RESOURCES........................................................................................................................................... 4
4.1 Equipments ...................................................................................................................................... 4
4.2 Personnel ......................................................................................................................................... 5
5 MATERIALS ............................................................................................................................................. 6
5.1 Consumable materials ..................................................................................................................... 6
5.2 Incorporated materials ..................................................................................................................... 7
6 OPERATING INSTRUCTIONS ................................................................................................................ 7
6.1 Principle............................................................................................................................................ 7
6.2 Sequences ....................................................................................................................................... 7
6.3 Quality Control (Inspection and Testing) Plan ............................................................................... 18
6.4 QC Reports .................................................................................................................................... 22
6.5 Precautionary Measures ................................................................................................................ 22
6.6 Health & Safety and Environment risks analysis ........................................................................... 23
Annex 1: QC Report
Annex 2: Health, Safety and Environment Risk Analysis
Annex 3: Estimated Trades and numbers of Personnel in each site
Annex 4: Equipment Brochures
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1 SCOPE
The purpose of this work procedure is to describe the method of installation of the horizontal soft gel plugs
to be installed between and near the bottom of the diaphragm wall for each station/structure of the “Greater
Cairo Metro Line No3, Phase 3” project as well as the main equipment, which is anticipated, for the
execution of the works.
2 REFERENCE DOCUMENTS
2.1 Contractual Documents

− Project Technical Specifications, 53M-TD-INF-ALL-SPEC-ACE-3001-T1, Soil Treatment.
2.2 Works Documents for Each Box

− Grouted Plugs Drawings.
− Bottom Stability of Grout Plug, Detailed Design.
− Design Manual.
3 GENERAL
In order to minimize the water ingress into each station/structure and to allow for excavating the site in
practically dry and safe conditions, soft gel grouted base plugs shall be installed near the bottom of the
surrounding diaphragm wall to form a tanking system. Plugs shall cover the whole site and should have a
permeability of not more than 1 x 10-6m/sec (Project specifications 53M-TD-INF-ALL-SPEC-ACE-3001-T1,
Soil Treatment, Section (6), Soil Treatment, Item 6.6.4)
Plug thickness and plug location shall be treated separately. Please refer to the “Detailed Design, Bottom
Stability of Grout Plug. This document shall cover also the plug thickness that shall be designed such that
the hydraulic gradient (i) < 3 (Project specifications Item 6.6.3).
In the design phase all available information regarding soil investigation, time scheduling, working area in
connection with equipment shall be considered to fix the grid of grouting pipes and valves, grout volume
and grouting procedure.
The soft gel plug durability is guaranteed for two years after starting pumping. This period is sufficient to
cover the contractual schedule.
4 RESOURCES
4.1 Equipments
For each site, and depending on the schedule of execution, one or more drilling set will be available
and operable. The main drilling equipment of each set are tabulated below (Small tools and equipment
is not listed)
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1 Nos. BG 28 Drilling Rig
1 Nos. Cement mixer BM 1000 or equivalent
As required Nos. Hose Pumps
1 Set Water Tank 10m³
1 Nos. Agitation Tanks
1 Nos. Compressor
As required Nos. Switch boards
The following machinery and their main spare parts shall be made ready and operable for each site
whenever they are needed for the grouting works. Small tools and equipment is not listed.
(If required to fulfill the schedule, additional and similar equipment shall be added)
Bauer Multi-Pump Container equipped with gel mixing

1 Nos.
plant (Min.13 pump)/container
1 Nos. Water tank(s) with pump
1 Nos. Grouting hoses with couplers
As required Nos. Silos/storage tanks for Sodium Silicates and Hardener
Please refer to Annex 4 for equipment brochures.
4.2 Personnel
− Estimated trades and numbers of personnel are attached in Annex 3.
− Working days per week shall be: six production days and one day for maintenance. (for
information)
− It is planned to work two shifts in each day of the six production days with a total of up to twenty
to twenty-four hours per day. This is for info only. Contract specifications shall be applied.
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5 MATERIALS
5.1 Consumable materials

5.1.1 Water
Tap potable water shall be used for dispersion of bentonite, sleeve mix and soft gel production.
5.1.2 Bentonite
Bentonite slurry is required for drilling operation, for stabilization of boreholes and for the
bentonite/cement mix.
The bentonite slurry is a mixture of activated bentonite powder and water. Bentonite is supplied in bags,
and will be stored close to the mixer in perfectly dry conditions.
The same bentonite type approved for the diaphragm walling works complying with project specifications
Item 6.4.c in section (6) soil treatment and Item 3.7.3 section (3) diaphragm wall shall be used
5.1.3 Grout pipes

Grout pipes of nominal diameter 3/8” shall be used for the grouting works. Pipes shall be in one piece
made of PVC. Material submittal form shall be submitted separately for approval prior to starting the
works.
5.1.4 Grout valves

Plastic valves fitted with manchette shall be used for the grouting works.
Grout Pipe
Grout Valve
Grout Valve
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5.2 Incorporated materials
5.2.1 Cement
Ordinary Portland cement will be used for the drilling and sleeve mixes.
5.2.2 Sodium silicates
Sodium silicates solution locally fabricated shall be used as the main component of soft gel grouting. As
per project specifications, Item 6.4.d section (6), the main properties of the sodium silicates solution are
as follows:
- Density (Baume) 36 to 40
- SiO2/Na2O = 3.0 to 4.0
For quality control please refer to Item 6.3.1.2 below, Quality Plan (Inspection and Test Plan)
5.2.3 Re-agent (Hardener):
Sodium aluminates solution shall be used as hardener for the above mentioned silicates. The density of
the sodium aluminates solution is in the range of 1.45 to 1.55gm/cm3
Material submittal form shall be submitted separately for approval prior to starting the works
For quality control please refer to Item 6.3.1.3 below, Quality Plan (In section and Test Plan)
6 OPERATING INSTRUCTIONS
6.1 Principle
The grouting process aims to replace the water and air in the soil with a soft gel solution. This is done
by means of low pressure pumping of a soft gel solution into the soil. Soft gel is a mixture of water,
sodium silicates (water glass) and hardener.
6.2 Sequences
The working sequence for the installation of a soft gel base plug comprises the following key phases:
− Site preparation and levelling phase
− Drilling phase which includes drilling, installation of grouting valves and pipes filling with the
sleeve cement/bentonite mix
− Grouting phase which includes installation of grout plug by injecting soft gel.
− Conducting a pumping test to assure the plug efficiency, refer to Item 6.3.5 below
− Pumping out of water seeping into the closed box. Item shall be carried out by the main
contractor.
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Drilling down to final level by drilling rig Removal of Drilling Rod and Filling with
Bentonite/Cement Grout
Installation of Grout Pipe and Valve Grouting of Soft Gel through Valve
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Drilling Flow Chart
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6.2.1 Drilling Phase
6.2.1.1 General
Drilling shall take place using extended mast Bauer’s drilling rigs. Bauer’s BG drilling rigs with
extended mast will be used for the drilling works.
The main advantages of using extended mast rigs is that a long portion of the drilling depth takes
place in one operation without the need to fix new segments every three or four meters like the
conventional methods of drilling.
This means less time and less deviation that may result between segments.
Also with these types of rigs, larger diameter of drilling rod (133mm) is used. This section of increased
inertia reduces deviations.
Drilling Rig with Extended Mast
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6.2.1.2 Drilling and Pipes Installation
The drill rod, ending with a drilling head, is advanced into the ground by rotary drilling assisted by
flushing with water and bentonite (900liters of water + 25kg bentonite). Cement is added to the mix
with a dosage of 150 to 250kg. Bauer type trilame drilling bit is normally used for drilling. However
different types may be used depending on encountered ground conditions. Also in most cases, drilling
is performed with a nominal diameter of 150mm (slightly larger than the drilling rod), however larger
diameters may be used in case required. Drilling depth is measured by a computerized monitoring
system located in the cabin of each rig. It should be noted that, if ground conditions require, the
drilling method and tool may vary depending on the actual encountered soil conditions.
While drilling, the return flow, mixed with soil is pumped out by a hose pump and sent to a desanding
unit, comprising screen and cyclone, to be recycled to be reused. The used fluid may be blended with
any of its components depending on its viscosity.
After reaching the final drilling depth, fresh new sleeve mix is pumped into the borehole through the
drilling rod to replace the dirty drilling fluid
Following this operation, the manchette valve or bundle of manchette valves connected to grouting
pipes are lowered into the borehole and fixed in place. All grout pipes will have the same top level to
assure that the grout manchettes valves are all at the same level. The whole bundle of grout pipes
and valves is lowered into the fluid supported bore-holes by hand. To assure that the bundle falls into
the borehole, a steel bar is connected to the bundle near its bottom to act as weight pulling the bundle
down.
The top level of the pipes is checked with a rotating level. Pipes are supported until the sleeve mix
hardens.
6.2.1.3 Drilling Rig Parameters
The drilling rigs are equipped with a special automatic monitoring device type B-Tronic. With this
device, the following parameters shall be automatically monitored and printed out:
− Depth
− Time
− Drilling speed
− Flow of Slurry
The above information shall be printed out in graphs indicating the variation of each item with depth of
boring. Example report is attached in Annex 1
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BAUER BG 28 with mast
extension and
133mm drilling rods
Rotary drilling system with
mud flushing
6.2.1.4 Verticality of Borehole

Verticality of all the boreholes is monitored during the drilling operation by the use of built-in
inclinometers that monitor the mast verticality. Deviations are displayed, during drilling, on a monitor
placed in the operator’s cabin.
In addition to the above, the verticality of five per cent of the pipes drilled per day per rig will be
counter checked by special in-hole inclinometer.
In this method, an inclinometer is lowered into the drilling rods to measures the deviations in two
perpendicular directions. An inclination report shall be printed after the measurement. An example
copy of an inclination report is attached below.
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Inclinometer Installation Readout Unit
In-hole Inclinometer Report
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6.2.1.5 Sleeve Mix (Water/Bentonite/Cement Mix)
A mix of bentonite, cement and water is used as sleeve slurry. The main function of the sleeve mix is
to support the grouting tubes and valves in place. Also it is needed to prevent the grout material from
travelling upward while grouting.
In case large pores or cavities are encountered at the level of plug (this shall be detected during
drilling if a loss of circulation is observed at the location of grout plug), encountered cavities of large
pores shall be reported and included in the report and shall be filled by the cement/bentonite
suspension during drilling. This is similar to gravity grouting. It should be noted that the fluid is injected
through the drilling rods is with the feed pump of a discharge of maximum 500 litres/min and pressure
of maximum 25 bars
If loss of circulation takes place, drilling depth and duration will be recorded.
Proportions of Bentonite/Cement Sleeve Mix
Item/Material Unit Quantity

Cement kg 150 to 250
Bentonite kg 20 to 40
Water litre 860 to 910
6.2.1.6 Drill Hole Pattern

As per the Design Manual, holes are distributed in plan in a triangular grid of spacing 1.60m
approximately. With this pattern, each point covers an area of 2.20m2. Please refer to figure below.
The gap between the first line of holes and the diaphragm wall is in the range of 0.35m to 0.80m
In each borehole a number of grouting valves are installed and connected to the surface with a
grouting pipe.
a
h
h a = 1.60m
h = 1.38m
Area covered by each hole = 0.866 a2
h
o
60
a a a a
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In each borehole along the vertical direction, valves shall be distributed at intervals of 1.0 to 3.0m to
cover the required plug thickness.
Minimum Plug thickness is 2.00 m and is covered by two valves
6.2.1.7 Sequence of drilling

Drilling shall be carried out in lines parallel to one end wall of the box and advancing to the other end
of the box. However, slight deviations on site may take place to allow for manoeuvring.
6.2.2 Soft Gel Injection
6.2.2.1 General
Soft gel injection may start after at least three days from installation of grout pipes and valves
In general grouting is performed by the use of one grouting container comprising at least thirteen
piston diaphragm pumps.
6.2.2.2 Mixing of Grout
Grout is mixed automatically in the grouting container. Mix varies depending on the required gelling
time that depends on the amount of grout to be mixed in one valve
The normal proportions of soft gel mix are tabulated in the following table:
Material Unit Quantity

Sodium Silicates kg 210 to 260
Sodium Aluminates kg 18 to 30
Water litre 830 to 800
6.2.2.3 Grouting Operation
After mixing of soft gel, each pump (periodically calibrated) shall be connected to a grout valve
through its pipe by a grouting hose.
The procedure for grouting each drilling point comprising several valves is as follows:
− Cover Fracturing
Prior to starting the grouting operation, the sleeve cover should be fractured. Cover fracture is
done by charging grout into the valve. In this stage, pressure rapidly increases till fracturing the
cover and then drops tremendously.
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− Phase (I), Pre-treatment
Soft gel grouting starts in the upper layer of valves. Grouting is performed with limited
quantities. The reason for this pre-treatment is to from grout bodies that partially cover the area
from top in order to prevent any uncontrolled up-flow when grouting through the lower valve
layers and force the grout to travel horizontally. This pre-treatment grouting does not cover the
whole area.
− Phase (II), Main Treatment
During this phase, the remaining valves are grouted with the design grout quantities. Grout
volume is calculated to fill all voids in the area covered by the point. Due to the existing pre-
treatment, grout will be forced to travel horizontally and then close the gaps between the pre-
treated points.
During this phase a complete membrane is formed that covers the whole area with the
specified thickness.
It should be noted that during grouting, quantity and pressure of grout for every grouted valve are
automatically monitored and recorded.
6.2.2.4 Grout Quantities
The volume of soft gel to be grouted through each valve is calculated as follows:
Grout Volume = ηxAxt
Where η : porosity
A : theoretical area covered by each point
t : part of plug thickness covered by the valve
The calculated quantity shall be distributed between the two phases indicated above [pre-treatment
and main treatment (finishing grouting)]. Quantities shall be as follows:
Pre-treatment in upper valve 50% of the calculated quantity
Second valve calculated quantity + the 50% remaining from the top valve
Middle valves calculated quantities
Lower valve calculated quantity assuming an increased covered area
resulting from deviation (Refer to detailed design)
The above represent the general procedure. However, it may vary according to site conditions
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6.2.2.5 Sequence of grouting in each level
In each level grouting in plan is conducted from the centre of an area going outwards
The closing beside the wall is done at the end to assure that the grout fills all the gaps near the wall.
Sequence of Grouting
2 1
6.2.3 Estimated Parameters
6.2.3.1 Drilling Feed Pump Maximum Parameters

- Discharge up to 500 litres/min
- Fluid pressure up to 25bars
6.2.3.2 Soft Gel Grouting Parameters

The following grouting parameters are given with a range and shall be adjusted for each site
during/after grouting first sleeve pipes.
Number of valves Depending on plug thickness

Maximum 50bars (If reached complete
Pressure for penetration grouting the valve then clean the
pumps
Flow rate 8 - 15 litre/min.
Grout volume per valve As per design
Note:
It should be noted that if the pipe is blocked, the remaining quantities are compensated for in the
surrounding points.
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6.3 Quality Control (Inspection and Testing) Plan
6.3.1 Quality Control for Material
6.3.1.1 Testing of fresh bentonite/cement sleeve mix

Sampling Sampling will take place at the mixing plant
Frequency of Testing Twice a day
Tests and Acceptance Criteria: Density of mix >1.10g/cm³ (project specs. Item 6.9.17)
March viscosity 34:45 sec (project specs. Item 6.9.17)
6.3.1.2 Testing of Silicate Solution

Sampling Sampling will take place at the storage tanks
Frequency of Testing Each delivery
Tests and Acceptance Criteria: Density 1.32: 1.45g/cm³
6.3.1.3 Testing of Reagent (Aluminates) Solution

Sampling Sampling will take place at the storage tanks
Frequency of Testing Each delivery
Tests and Acceptance Criteria: Density 1.45 : 1.55g/cm³
6.3.1.4 Testing of the soft gel
Sampling Sampling and testing will take place from the soft gel basin in the
Pump container just after mixing
Frequency of Testing Twice a shift
Tests and Acceptance Criteria: Density 1.04: 1.10g/cm³
March viscosity 28 : 35sec
Gelling time Shall be estimated for each level of valves in each site
depending on the quantity to pumped per valve.
6.3.2 Quality Control for Execution

Bore point drilling points will be marked by a surveyor and the drilling/grouting superintend.
Borehole verticality please refer to Item 6.2.1.4 above
Sleeve mix All parameters shall be monitored and printed-out and submitted to NAT
Soft gel mixing shall be done by a computerised central mixing and grouting system with
Automatic documentation of mix proportion, grouting pressure, flow rate and grout
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volume. Gelling time for soft gel shall be checked two times per shift.
Injection report at the end of grouting operation, a report shall be printed out for each point
including the following information:
− mix proportion
− grouting pressure
− flow rate
− grouted volume
An example report is attached in Annex 1.
Computerized Monitoring Unit in Grouting Container
6.3.3 Calibration
After each mobilization to a station/annex and prior to starting the works, all pumps are calibrated for
pressure and discharge.
Calibration of pressure gauges is performed by fixing a calibrated reference pressure gauge at the
pump outlet. The pressure reading of pump gauge is compared to the pressure reading of the calibrated
reference gauge
Discharge is calibrated by pumping water into a tank of known volume and comparing the discharge to
the plant reading
6.3.4 Records
Construction and Inspection & Test Records to be maintained during, and on completion of the work for
quality and maintenance purposes
The following table describes specific parameters that will be recorded during the grouting operation.
The table further identifies either where the information will be recorded or which individual or group will
be responsible for gathering the information.
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Parameter Responsible Party
No. and Depth of hole injected Drilling Rig Staff
Mix Proportions Mixing Plant Staff
Density of Cement-Bentonite sleeve Mix Mixing Plant Staff
Mix Proportions Chemical Grout Grouting staff
Density of Chemical Grout Grouting staff
Gelling time of Chemical Grout Grouting staff
Volume grouted per valve Grouting staff
grouting Pressure Grouting staff
flow rate Grouting staff
NAT and QC representatives are in addition to the above
The Drilling record shall include the following information:

- Description of the work completed with a sketch identifying which sleeve pipe is completed.
- Location of drilling point and valve pipe.
- Time of beginning and completing of each valve.
- Sleeve mix data, including mix proportions, volume, and density of sleeve mix used to install
valve pipes at drilled holes.
Please refer to sample report in Annex 1.
The Grouting record shall include the following information:

- Location with time of beginning and completing of each valve to be grouted.
- Total grout quantity used for each valve
- Opening pressure from the sleeve valve.
- Grout pressure during grouting.
- Final grouting pressure.
- Flow rate during grouting.
- Please refer to sample report in Annex 1.
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6.3.5 Pumping test
In order to minimize the water ingress into each individual box in every station/structure and to allow
for excavating the site in dry and safe conditions for the works and the adjacent buildings, grouted
base plugs shall be installed near the bottom of the surrounding diaphragm wall to form a tanking
system. Plugs shall cover the whole box area. As per project specifications, plugs should have a
permeability of not more than 1 x 10-6m/sec.
At the end of box grouting and prior to dewatering, a pumping test shall be conducted to check the
efficiency of the grout plug and to assure that the plug permeability is within the specified limit.
It is proposed to install one well, two piezometers inside the box enclosed by diaphragm walls, cut-off
(slurry) walls and grout plug.
To monitor the drawdown (if any) outside the grouted box, the outer piezometers previously installed
by the JV shall be used for monitoring the outer water table during testing. Also, piezometers installed
in neighbouring boxes shall be monitored.
In order not to affect the grouting pipes protruding out of the ground, boreholes needed for wells and
piezometers shall be drilled down manually. Wells should be higher than the top of plug.
The well will be used to lower the water table within the site boundaries. The safe drawdown shall be
determined by the diaphragm wall designer. While dewatering, the water level will be monitored by
the piezometers. After reaching the required drawdown, pumps will be regulated to reach the steady
state.
Steady state is reached when the water level does not change more than ten centimeters in half an
hour.
Based on the measured discharge and the water levels after reaching the steady state, the
permeability (k) of the plug will be calculated using the following formula:
kp = Qp / [i x A] m/sec
Where kp : Plug permeability (m/sec)

Qp : Water discharge through plug (m3/sec)
i : Hydraulic gradient acting on plug
Ap : Surface area of plug (m2)
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D-Wall
D-Wall
Grout Plug Qplug
6.4 QC Reports
QC Reports for grouting works Annex 1
6.5 Precautionary Measures

Two contingency plans shall be ready against deficiency or emergency that may occur during the
construction activities. The first plan covers the period after grouting and prior to excavation. The
second one covers the period during and after excavation.
Contingency Plan after Grouting and Prior to Excavation
− As explained above, after grouting all grouting parameters shall be reviewed and a
comprehensive report shall be prepared.
− A pumping test shall be conducted for the grouted closed box.
− If pumping test shows any deficiency in grout plug (plug permeability is higher than specified),
re-grouting may take place. Quantities shall be estimated in Bauer’s main office in Germany and
the remedial measures shall be submitted for NAT review prior to taking any action.
Contingency Plan during and after Excavation

− After excavation, water levels in outer and inner piezometers shall be monitored in addition to
the water flow.
− If a sudden increase in water flow associated with continuous drop in water level in outer
piezometers, responsible personnel from the JV, Bauer and NAT shall be informed and a quick
remedial action shall be proposed and followed.
− For example, the excavated box shall be evacuated and flooded with water to stabilize the plug.
− A list of responsible personnel including their mobile phones shall be prepared by each party
and shall be available on site for such emergencies.
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6.6 Health & Safety and Environment risks analysis
Health, Safety and Environment risk analysis is attached in Annex 2.
6.6.1 Health and Safety

In addition to the ordinary health and safety, the following shall be considered:
• Mixing plant
- All workers working in the bentonite/cement mixing plant shall wear dust masks goggles.
- Workers shall wear gloves for bentonite/cement handling.
• Drilling operation
- Only designated trained personnel shall guide the drilling rig operator while moving and
adjusting the rig in place.
- Working platform shall always be well compacted and level prior to moving of heavy
equipment.
• Grouting works
- All workers dealing with grout shall wear gloves.
- All workers working in grouting container or in front of grout pipes shall wear protecting
goggles.
• Moving and lifting equipment (During unloading/loading)

- Lifting loads shall be always less than the maximum safe capacity of the equipment.
- No load shall be left suspended by the equipment.
- No work shall take place under lifted loads.
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6.6.2 Environment
In addition to the ordinary environmental rules, the following shall be considered:
− Used oil shall be collected while changing in order not to contaminate the ground and shall be
disposed safely in designated areas.
− Equipment shall be fuel fed by manual pumps through hoses in order to avoid spillage on the
ground.
− Backflow Material shall be collected in a basin and to be disposed off the site by the main
contractor.
− Waste bentonite shall be collected in tanks to be removed by the main contractor.
Annexes
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ANNEX 1:
Quality Control Reports
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EGYPTIAN-FRENCH JV FOR CIVIL WORKS
Subcontractor: EGYPT
PROJECT : Greater Cairo Metro Line 3

Drilling Report
Date/shift: / day - night Verticality: _____________________°
Supervisor ____________________________ Working platform ___________________
Drilling rig: ____________________________ Density of sleeve mix: _________________g/cm³
Drilling diameter: ____________________________
Plan No..: Plan No..: ______________________
Drilling time Location of valves Drilling

Borehole No. Vol. - sleeve mix Length of grout pipe
Start End V1 V2 V3 V4 V5 V6 depth
[/] [ m³ ] (h /min) (h/min) [m] [m]
Bauer ___________
JV ___________
Drilling and Jetting Report
Jobsite:
Client: BAUER MASCHINEN GmbH Project Id.: AIF MASAKAN
Operator: AHMED FOUAD Column No.: 148-14
Helper: Date: Aug 26, 2015
Drilling Rig: BG 28 Filling Pump: MONO PUMP T. length of borehole: 30.02 m

Inclination: 0°
Rod diameter: 133 mm
Start time: 2:53:33 ... Channel I: Channel II Channel III

End of drilling: 3:15:44 ...
Start of jetting: 3:15:44 ...
End of jetting: 3:19:56 ...
Total Time: 00:26:08
Penetration Rate [min/m] Torque [%] Flushing Flow Rate [l/min] Crowd-Force [t]
0.00 0.00 0.00 0.00
3.00 3.00 3.00 3.00
6.00 6.00 6.00 6.00
9.00 9.00 9.00 9.00
12.00 12.00 12.00 12.00
15.00 15.00 15.00 15.00
18.00 18.00 18.00 18.00
21.00 21.00 21.00 21.00
24.00 24.00 24.00 24.00
27.00 27.00 27.00 27.00
30.02 30.02 30.02 30.02

10.8
11.9
105
140
175
209
244
279
314
349
384
0.0
0.1
0.3
0.4
0.6
0.7
0.9
1.0
1.2
1.3
1.5
1.6
0.0
1.1
2.2
3.2
4.3
5.4
6.5
7.6
8.7
9.7
15
23
30
38
45
53
60
68
75
83
35
70
0
8
Remarks:
Superintendent: Client: N
X: mm
W E
+
Y: mm
S
BAUER Maschinen / Spezialtiefbau GmbH - D-86522 Schrobenhausen - Telefon +49 8252/97-0
EGYPTIAN-FRENCH JV FOR CIVIL WORKS
Subcontractor: EGYPT
PROJECT : Greater Cairo Metro Line 3

Injection Report
Date: Operator: day / night page no. __________
Density Viscosity Gell. time
Location of Injection Quantity Injection Flow Starting Injection

Borehole No. Pump No. remarks
valve (mNN) (L) Rate (L/min.) pressure (bar) pressure (bar)
Bauer
JV
ANNEX 2
Health, Safety and Environment Risk Analysis
BLACK A4 31/39
WORK PROCEDURE FOR
GROUTED BASE PLUGS
9 4 0 G 2 B A U 3 0 0 W 0 0 7 A -
HEALTH AND SAFETY RISKD ANALYSIS FOR SOFT GEL GROUTING
(HAZARDS CHECK LIST)
TASKS HSE RISKS CONCLUSIONS
Mobilization ,Setting up, Load

displacement
Setting-up of the platform of work Fault in the platform of work Check that all mechanical components
are working
Check the conformity of drilling rig
The platform must be stable and clean.

Setting up of lifting Overturning Qualified personnel must check the
Electric shock electrical installations.
Check the excavated soil:

Preparation of the execution of works Local environment - on the ground: good stability and
without obstacles
- in depth: no live pipes or wires
- Overhead: no electrical lines
Borehole drilling
Drilling of boreholes Getting run over Check:

- clearance of work area; no waiting
nearby the machine,
- no access in the area for other
personnel than excavation team,
Due to local environment Check the position of he known pipes,

electrical line and mark out the
underground networks
Due to traffic Traffic control and layout and marking

the traffic lanes
Fabrication of cement- bentonite

slurry
Area of fabrication is cleaned and
Falls drains to evacuate mud and water are
Setting up put in place.
Slips Stocking area is closed to the
fabrication area
Fabrication of the slurry Dusts The slurry mixer has to set up with
anti-dust masks.
Check the hoses and the sluice-gates

Traffic Getting run over
Clean areas around slurry mixer for the
truck traffic.
ANNEX 3
Estimated Trades and numbers of Personnel in each site
BLACK A4 33/39
WORK PROCEDURE FOR
GROUTED BASE PLUGS
9 4 0 G 2 B A U 3 0 0 W 0 0 7 A -
Estimated Trades and Numbers of Personnel for Grouting per Day
Trade/Profession Drilling Grouting`
Engineers
3 2
(Management, Construction & QC)
Grouting Foremen 2
Maintenance Engineers 1
Administration
Accountants 1 1
Store Keepers 2 1
Safety Officers 1 1
Operators 4 2
Drilling Foremen 1 1
Surveyors/Helpers 2 1
Mechanics & Helpers 2
Electricians & Helpers 2
Welders / Helpers 2 -
Drivers 1 1
Skilled Labourers 20 14
ANNEX 4
Equipment Brochures
BLACK A4 35/39
WORK PROCEDURE FOR
GROUTED BASE PLUGS
9 4 0 G 2 B A U 3 0 0 W 0 0 7 A -
Drilling Rig BG28 with Extended Mast
Page no.: 06.07.001.01.1
TECHNICAL DETAILS
Date/signature: 2006-03-06 dam-wek
Grouting container with 13 pumps

- Grouting container -
Pumps 13 pumps
Flow rate 5 - 25 l/min
Pressure 70 bar
Mixer Flow mixer
Mixing power 190 l/min
Mixing components 3
Control Fully automatic grouting process with preselection of
quantity and pressure fully automatic mixing plant
Recording Registration of injection data (time, pressure, quantity) and
dosage of mixing components trough B-tronic
Transport measurement Length 12 055 mm
Width 2 435 mm
Height 2 585 mm
Weight appr. 14 000 kg
E-Power 52 kW
Electric power supply 400 V, 50 Hz, CE-standard plug connection plug 125 A, 5
phases, assembly socket 32 A 5 phases
Connections Soft gel ¾"-nipple
Water C-standard cuppling
Water glass C-standard cuppling
Hardening agent C-standard cuppling
BAUER Spezialtiefbau GmbH • 86529 Schrobenhausen 06-07-001-01-1_Injection-Container.doc

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Table of Index

Type: Scale: Folio: Pages:

Type: Scale: Folio: Pages:

2.1 Contractual Documents

2.2 Works Documents for Each Box

Type: Scale: Folio: Pages:

1 Nos. Cement mixer BM 1000 or equivalent

As required Nos. Hose Pumps

1 Set Water Tank 10m³

1 Nos. Agitation Tanks

As required Nos. Switch boards

Bauer Multi-Pump Container equipped with gel mixing

1 Nos. Grouting hoses with couplers

As required Nos. Silos/storage tanks for Sodium Silicates and Hardener

Please refer to Annex 4 for equipment brochures.

Type: Scale: Folio: Pages:

5.1 Consumable materials

5.1.3 Grout pipes

5.1.4 Grout valves

Type: Scale: Folio: Pages:

5.2.2 Sodium silicates

5.2.3 Re-agent (Hardener):

Type: Scale: Folio: Pages:

Type: Scale: Folio: Pages:

Type: Scale: Folio: Pages:

Drilling Rig with Extended Mast

Type: Scale: Folio: Pages:

6.2.1.3 Drilling Rig Parameters

Type: Scale: Folio: Pages:

6.2.1.4 Verticality of Borehole

Type: Scale: Folio: Pages:

In-hole Inclinometer Report

Type: Scale: Folio: Pages:

Proportions of Bentonite/Cement Sleeve Mix

Item/Material Unit Quantity

6.2.1.6 Drill Hole Pattern

Type: Scale: Folio: Pages:

6.2.1.7 Sequence of drilling

6.2.2 Soft Gel Injection

6.2.2.2 Mixing of Grout

Material Unit Quantity

6.2.2.3 Grouting Operation

Type: Scale: Folio: Pages:

6.2.2.4 Grout Quantities

Type: Scale: Folio: Pages:

6.2.3 Estimated Parameters

6.2.3.1 Drilling Feed Pump Maximum Parameters

6.2.3.2 Soft Gel Grouting Parameters

Number of valves Depending on plug thickness

6.3.1.1 Testing of fresh bentonite/cement sleeve mix

March viscosity 34:45 sec (project specs. Item 6.9.17)

6.3.1.2 Testing of Silicate Solution

6.3.1.3 Testing of Reagent (Aluminates) Solution

6.3.1.4 Testing of the soft gel

6.3.2 Quality Control for Execution

Borehole verticality please refer to Item 6.2.1.4 above

Type: Scale: Folio: Pages:

Computerized Monitoring Unit in Grouting Container

Type: Scale: Folio: Pages: