Punatsangchhu- II Hydroelectric Project Authority

Office of the Engineer In-Charge

(Ph. # 02-471618, Fax # 02-471619, email: [email protected])

NOTE SHEET

Sub: Contract Agreement No.C3/2011 dated 25.7.11: Construction of Head Race Tunnel from
Surge Shaft end, Surge Shaft, Butterfly Valve Chamber, Pressure Shaft, Power House and
Tail Race Tunnel including Hydro-Mechanical works of the 1,020MW Punatsangchhu-II
Hydroelectric Project, Bhutan: Proposal to implement FMI Construction Methodology for
installation of additional permanent rock bolts for strengthening of underground Power
House Complex - Seeking of Technical and Administrative Approval and Financial
Concurrence thereof.
The incidence of rock fall in DSSG on 3 rd March 2016 have affected the stability of all other main
underground caverns of the Power House Complex. Since then, the designer together with other
relevant agencies and experts have been trying to understand the effect of the rock fall and
formation of cavity in DSSG and its remedial measures. By 30 th June 2016, designer had issued
strengthening measures to be implemented for the invert and wall of the underground
Transformer Hall and by 11th August 2016, strengthening measures for the crown of the
underground TH was also issued. On 21st December 2016, strengthening measures for the
Machine Hall have also been issued to PHPA for implementation.
The design for the strengthening measures issued as above involved carrying out consolidation
grouting of the rock mass through long grout holes; installation of additional 36 mm dia. resin-
grouted end-anchored type rock bolts fully cement grouted at 1.5 m c/c spacing and staggered.
For the Transformer Hall, the designer has stated to use resin end-anchored type rock bolt with
full cement grout to be pumped into the borehole; while for the Machine Hall, it is stated to use
fully grouted rock bolts at 1.5 m c/c spacing and staggered. Designer has stated not to use
capsules but carry out grouting of rock bolts using pumps.
Strengthening measures in the Transformer Hall was taken up in December 2016. However,
during the course of execution, many practical problems were being encountered and the work
could not be executed smoothly. As such, a meeting was convened by the EIC (PH) on 14 th
January 2017 at the MAT Contractor’s office to discuss the issues along with representatives from
Geology, Quality Control and the Contractor. The issues have been recorded in the minutes of the
meeting (Annexure-I). Briefly, the main issues with the current methodology of rock bolt
installation are on account of the longer length of bolts which tend to bend, face increased
resistance to bolt insertion in small diameter boreholes, use of coupler for the bolts, use of resin
capsules in water-logged drill-holes in fractured and schistose rock mass, lack of full cement
grouting of the bolts, blockage of boreholes during bolt insertion leading to improper and
incomplete installation of bolts, uncertainty in the end-anchorage of rock bolts by resin cartridges
which get mixed with cement grout and water during insertion, uncertainty of full embedment of
bolts by cement grout for corrosion protection due to long length boreholes which are generally
not straight, etc.
As result of the practical problems, it was found that the current methodology followed for
installation of rock bolt supports for the important permanent strengthening of the structure like
Power House is not ensuring a fully effective support system which is expected to serve the
designed service life of the structure.
The above mentioned practical problems have also been discussed during the 74 th PRM held on
4th February 2017 during which the management instructed EIC (PH) and the contractor to attend
to all the problems and execute the works properly in view of the critical situation of the
underground structures. However, till now no improvements could be made on the rock bolt
installation methodology and the same process is being followed.
PHPA, however, with the initiative of JMD have since then taken up with M/s Freyssinet Menard
India Ltd. (FMI), New Delhi who had executed the installation of Permanent Bar Anchor job (15 m
long 36 mm dia. 1000 kN bolt) in the large size (23 m span) underground Power House of
Dagachhu Hydropower Project. The performance credibility of such works by FMI is best known
by the JMD, PHPA who then served as the interim CEO of Dagachhu Hydropower Project.
PHPA-II, therefore requested FMI to visit our project site, which they did on 2-4 th March, 2017 and
made presentation of the permanent bar anchor support system to the management in the office
of the Managing Director on 2nd March 2017. The management made clear to FMI that at this
point the support system design shall remain same but it is only the construction methodology
which need improvement over the current method of rock bolt installation for which FMI
assistance is required.
Subsequently, representatives from PHPA-II visited the office of FMI at New Delhi from 24-26 th
March 2017 to work out the modalities to involve FMI. During the meeting, the scope of works
and certain terms and conditions have been drawn through a minutes of meeting (Annexure-II)
to form the basis.
Based on the minutes of meeting, FMI has submitted their offered rates for providing technical
assistance in implementing the construction methodology for the rock bolt installation along
with some supply of essential accessories required for proper execution of the work (Annexure-
III). The summary of the financial implication is shown in Table below:
Item Description Qty. Rate Amount (INR/Nu.)
(INR/Nu.)
1 Supply of all complete accessories 3,500 Nos. 18,950.00 66,325,000.00
related to rock bolting works, 15 m long.
2 Technical Support and Supervision- 52,500 m 770.00 40,425,000.00
Services
3 Total 106,750,000.00
In the above, the quantity of rock bolts has been taken tentatively in order to enable the firm to
firm up a certain rate for the work. The quantity could be subject to variations. Further, details for
the supply part are as given in the detailed document, which include HDPE pipes for sheathing of
bolts for double corrosion protection, HDPE hose pipes for grout delivery and air vents; purchase
of imported expandable packers for high pressure grouting to consolidate the drilled boreholes
in schistose and fractured rock mass, end-caps, spacers for proper bolt alignment and proper
embedment of bolts in grout, non-shrink grout admixtures, etc.
It is pertinent to mention here that the FMI method of rock bolt installation would guarantee
long term durability of all the bolts with double corrosion protection (full cement grout coverage
and HDPE sheathing with heat-shrink couplers) in addition to assurance of 100% effectiveness
which will be proven through 100% testing of bolts during application of stressing of each and
every rock bolt. This level of quality assurance in ensuring the effectiveness of the additional rock
bolt supports for strengthening measures of Power House is expected to provide a much better
confidence to all the stakeholders of the project from the two governments.
Further it has been found that some literature also caution the use of resin-grouted rock
reinforcements for large permanent excavation which states, “Long resin-anchored bolts should
not be used as primary support in large permanent excavations and resin anchored bolts should not
be longer than 3 m”. “The best long-term performance for cement and resin-grouted installations
can be provided by a double barrier of epoxy coated bars and full encapsulation with cement and
resin. A longer design life (100 years) is assured by a double corrosion protection system consisting
of a sheath where the internal grout acts as the second physical barrier. Grout that bonds to the
rock is not acceptable as a physical barrier because of the inevitable defects” (Annexure – IV).
Considering the continuing shooting rock bolt failures being experienced in the Power House of
Tala Hydropower Plant even after more than a decade into operation stage, it is genuinely felt
that one need to be extra careful regarding the installation of primary rock supports in such an
important structure.
A senior expert on geotechnical and tunnel engineering from M/s Bernard Engineers, Austria also
advised us that since there is no permanent inner lining in the cavern, the rock bolts serve as
permanent stabilization of rock mass and hence should be with a double corrosion protection. He
opined that resin grout is used when excavation is in progress in order to achieve early strength
and enhance production; while for strengthening as done now, early strength is not decisive
since excavation has happened long ago and for rock mass strengthening and for longer service
life, fully cement grouted rock bolt should be reconsidered.
In view of above, it is submitted for kind perusal of this proposal to engage the service of M/s FMI
to implement a better alternative construction methodology for installation of long length rock
bolts for strengthening measures of the underground caverns of the of Power House Complex
along with supply of essential materials and accessories required for the work. The design
parameters of the supports shall remain same as issued by the CWC viz. the type of steel for rock
bolts will be HYSD re-bars Fe 500 Grade, 36 mm nominal diameter, installed at spacing of 1.5 m c/c
and staggered and pre-tensioned to load of 12T but the bolts will be completely sheathed in HDPE
pipe and borehole periphery completely grouted by pumping cement grout. Secondary grouting
of the free-length portion of the bolts inside the HDPE pipes shall be carried out after providing
pretension load and then bolts properly locked with nut exactly at the specified load.
The Technical and Administrative approval and Financial Concurrence of the Competent
Authority for the same is sought herewith so that the work may be awarded to M/s FMI directly
without having to go through the normal process of tendering in view of the lack of availability of
such expertise in the country as well as due to immediate requirement to involve the agency to
take up the strengthening works in the Power House with installation of additional long length
rock bolts.
Submitted please.

(Gorab Dorji)
Engineer In-Charge (PH)

Director (Technical)