The DeRuyter Reservoir, in DeRuyter, New York, is a 557 reservoir originally developed as part of the Erie Canal system.
As part of a dam upgrade project, the three parallel 22″ diameter, 300LF outfall pipes needed to be abandoned, along with a stone box culvert downstream of the valve chamber the pipes terminated into.
Each of the three pipes had been previously blindly flanged by divers. Therefore, the only access was from the downstream end within the valve chamber. In order to vent the air displaced by the abandonment grout, vent or placement points needed to be installed just behind the upstream blind flanges, which were approximately 40′ below the water surface.
CJGeo worked with the general contractor to design an internal venting system utilizing sacrificial placement pipes installed from the valve chamber. After each of the sacrificial grout pipes was installed, the downstream terminations were bulkheaded, with vent stubs.
CJGeo mobilized a cellular grouting crew, who placed 30lb/cuft cellular concrete through each of the sacrificial grout pipes, until grout returned to the bulkhead vents, confirming fill. The work was completed over two days an onsite-the first day for the abandonment pipes and first lift in the box culvert, and the second day for a top-off pour on the box culvert.
Lake Whetstone is an approximately 30-acre manmade impoundment located in Montgomery Village, Maryland. It is utilized for stormwater runoff control, and also recreation, with an approximately 1000LF earthen dam.
As part of a retrofit program of the embankment, two 8″, perforated CMP toe drain pipes need to be grouted for a minimum of 100LF, underactive flow.
Each of the two, 100′ long pipes needed to be grouted full, but could only be accessed from the downstream end of the pipes. One pipe had nominal flow, and the second pipe had approximately 10GPM and discharged through an end wall structure at the stilling basin.
The project designer, Gannett Fleming, specified NSF Section 61 certified grout (potable water contact) for the abandonment grout. Due to the “one-shot” nature of the project, above-ground mockups, including sacrificial pipe installation, chemical grout cup testing, yield analysis, and visual inspection, were all required prior to the start of grouting.
CJGeo performed the onsite mockup testing and analysis, and then grouted the two pipes in place successfully over a period of two days onsite.
A 36″ RCP outfall pipe for a dam terminated at an end wall. As part of a dam rehabilitation, small seeping leaks at the end wall/pipe joint needed to be stopped. The leaks had to be stopped so the wall could be resurfaced.
The engineer specified chemical grouting.
Access to the area was quite difficult. It was more than 150 feet from the closest vehicle access, which was only accessible by 4×4 vehicles down a steep slope.
While unknown during the planning of the chemical grouting repair, what was thought to be 36″ RCP was actually a larger diameter RCP that had been lined with steel casing pipe. An interior poured-in-place concrete liner had been installed afterward.
Super low viscosity prepolymer chemical grout was selected. This was for two reasons: 1) the ability to easily pump more than 150LF from the lay-down area. and 2) the ability to seek out and stop leaks through very tight cracks in the structures.
Prepolymer chemical grouts are water-reactive, so can be injected into active water flows. The grout expands when it comes into contact with the water, which seals the leak.
The initial grouting plan was to install the chemical grout through the pipe wall starting beyond the first joint. However, because the pipe had been cased, placement had to be done through the end-wall structure only. Multiple injection holes were drilled through the end wall structure, and the chemical grout was pumped through the end-wall structure.
Extensive catalyzation was used to first seal the leaks at the end wall and then chase the water flow pathways up along the outside of the pipe. The job was messy due to the forced proximity of the injection points and the leaks. But all the leaks were successfully stopped.