Standard Operating Procedures

G3 System G3 System

Chennaii Mettro Raiill Projjectt Chenna Me ro Ra Pro ec

Ref. N 1000000 Prepared by: Jorge Capito-Mor

GEO - Ground Engineering Operations 81 Oxford Street London W1D 2EU United Kingdom Phone: +(44) 20-7903-5109 Fax: +(44) 20-7138-2564

Verified by: Kamlesh Kumar Mishra

Date: th 28 July , 2010

The information in this document is confidential and property of GEO. Reproduction or distribution of this document without GEOs consent is strictly prohibited. Total or partial copies of this document cannot be given or distributed to third parties without prior consent from GEO. GEO Acknowledges all trademarks cited in this document from third parties.

Standard Operating Procedures

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INDEX

Key equipment and Designs required for best use of the G3 system .................................... 2 1.1 1.2 1.3 1.4 1.5 1.5.1 1.5.2 Water supply .......................................................................................................................... 2 Positive Head pressure ........................................................................................................ 2 The mixing tank ..................................................................................................................... 2 Storage and Sedimentation tanks ....................................................................................... 3 Excavating tool ..........................................................................Error! Bookmark not defined. Drilling Bucket .......................................................................Error! Bookmark not defined. Grabs .................................................................................................................................. 1

Description and usage of the G3 system .................................................................................. 1 2.1 2.2 2.3 PolyMud ................................................................................................................................ 1 MicroBond ............................................................................................................................ 1 AlfaBond ............................................................................................................................... 2

2.5 PolyGel ...........................................................................................Error! Bookmark not defined. 2.1 Super DSand Cleaning ........................................................................................................ 2

2.6 Super DSand Disposal .................................................................Error! Bookmark not defined. 3 Technical specifications and key slurry properties to be monitored ....................................... 3 3.1 3.2 3.3 3.4 3.5 3.5.1 3.5.2 3.6 3.7 3.8 4 5 Viscosity................................................................................................................................. 3 pH ............................................................................................................................................ 3 Specific weight or Density ................................................................................................... 3 Sand Content ......................................................................................................................... 3 Sampling for monitoring and quality control purposes .................................................... 4 Sampling Procedure for Diaphragm Wall ....................................................................... 4 Sampling Procedure for Piles ..............................................Error! Bookmark not defined. Slurry specifications for Diaphragm Wall Project ............................................................. 4 Slurry specifications for Pile Project ......................................Error! Bookmark not defined. Improving the performance of the G3 system .................................................................. 5

Environmental impact ................................................................................................................... 6 Disclaimer ....................................................................................................................................... 6

Standard Operating Procedures

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1 Key equipment and Designs required for best use of the G3 system
Dew to the unique characteristics of the G3 system there are several important procedures to be followed in order to ensure the products best performance.

1.1 Water supply An appropriate supply of water must be available at all times. If the quantity of water is considered insufficient, a tank or tanks for storage purposes should be dedicated to the plant according to the projects needs. Whenever the usage of brackish or salt water is required for mixing, GEOs Technical Services will advise about the necessary changes. 1.2 Positive Head pressure A minimum of 3 meters of slurry head pressure should be maintained above the water table at all times. Plans for the design and building of the working platform should take this factor into consideration. If this cannot be achieved through working platform design or implementing a raised casing GEO recommends the usage of AlfaBond in order to increase the slurrys specific weight or density.

1.3 The mixing tank The mixing tank shall be installed taking into consideration the slurrys need for constant agitation. This can be achieved by dedicating a pump and compressed air system to the mixing tank. In case of preference by the site manager in the usage of centrifugal pumps, the speed should not exceed 60 to 100rpm. GEO recommends the usage of diaphragm or piston pumps for best results. Centrifugal pumps should never be used for mixing. In order to allow a faster hydration of the polymer, a metallic plate should be welded directly o underneath the flow of water directed into the tank and inclined approximately 45 . If the water flow or the slurrys agitation are insufficient versus the rate of addition of the dry polymer granulate, the formation of inert agglomerates will occur, thus resulting in a higher consumption than initially expected. The capacity of the storage tanks should take into consideration the excavations volumes and pretended production rates preferably exceeding it 1,5 times.

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1.4 Storage and Sedimentation tanks Storage of slurry can be made in tank and silos and should have the capacity for a minimum 3 volume of 20m . The sedimentation tank shall be open on top to allow an easy cleaning and removal of sediments. The inclusion of two deflective vertical metal plates will assure the continuous flow of the slurry in a cascade like mode, increasing the speed of sedimentation occurring between different compartments or sections. This design causes a significant increase of the sedimentation process. The inlet valve shall be directed to the top of the first deflective vertical plate. Both valves should be placed at the same height from the top of the deflective plates.

1.5 Batching Plant schematic The installation of the slurry plant must allow all operations to be carried out at the same time. Mixing, sending and receiving slurry without interfering with production rate. Additional technical advice concerning plant installation will be provided when previously request by the client. The sedimentation tanks are extremely important in the returning slurrys self-cleaning process by sedimentation and must be incorporated in a batching plant layout.

Standard Operating Procedures 1.5.1 Batching Plant Schematic Example 1

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LEGEND 1234567891011Silos Slurry Storage Mixing Tank Water storage Sedimentation Tank Positive displacement Pump Air compressor Slurry Supply line Slurry return line Bidirectional slurry line Valves Diaphragm Wall Panel

GEO GROUND ENGINEERING OPERATIONS

Standard Operating Procedures

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1.5.1

Batching Plant Schematic Example 2

LEGEND 12345678910Slurry Storage Mixing Tank Water storage Sedimentation Tank Positive displacement Pump Air compressor Slurry Supply line Slurry return line Valves Diaphragm Wall Panel

Standard Operating Procedures

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1.6 Grabs For fluid loss optimization of the slurry we strongly recommend the grab to have holes to allow the excess of slurry flow back to the excavation upon retrieval from the excavation.

2 Description and usage of the G3 system

2.1 PolyMud

Synthetic dry granular biodegradable polymer should be mixed with water at an initial rate of 3 1Kg per m . Before adding PolyMud the water pH should be adjusted to 11/12. For a correct adjustment of the waters pH, we advise the usage of Sodium Hydroxide or Potassium Hydroxide in a 3 concentration of 45 a 50% in a rate of 1 liter per m of water. If purchased in dry flakes the 3 correct amount is 0,5Kg per m de water. With the initial recommended dosage and after previous treatment of the waters pH the viscosity will be between 60 e 70 seconds per quart (API Marsh Funnel). The slurrys viscosity should be maintained greater than 55 seconds at all times for best results. PolyMud maintains its properties through time provided that is not exposed to high concentrations of chemical contaminants, such as calcium carbonates, magnesium, calcium and chlorine amongst others. The values above were calculated considering the usage of an adequate mixing tank. Whenever the usage of tanks is not possible, with direct mixing at the excavation, the required dosages may be higher with no harm whatsoever to products best performance. GEO recommends that whenever possible the mixing should be preferably done in a proper mixing tank. However, depending on general circumstances such as, lack of space or soil conditions, it may be necessary to add PolyMud directly at the excavation. The application of this method has several advantages like increased slurry viscosity and an overall stabilization of the formation helping to prevent fluid loss and improving the slurrys performance.

2.2 MicroBond

MicroBond is the newest component of the 'G3' System. This liquid polymer promotes 'microbonding' of the PolyMud and AlfaBond polymer molecules, to generate a unique 'three dimensional framework' of polymer stability. MicroBond is primarily used when difficult or unpredictable soil conditions are encountered. Intrinsic data shows improvements in slurry performance and characteristics when Micro Bond is incorporated into the 'G3' System. Its primary purpose is to strengthen the anionic and associative groups of the polymer's matrix, but it is commonly used as a catalyst for the different sedimentation and cleaning processes of both the excavation or sedimentation tanks. MicroBond is available in liquid form and is mixed with water. The amount of product used varies with the intended application, usually in solutions of 10% to 25%. For local applications, these solutions can be added directly at the excavation or in plastic bags with a weight to sink it.

Standard Operating Procedures 2.3 AlfaBond

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AlfaBond is a liquid variation of the PolyMud polymer, exclusively designed as a 'multi-role' polymer cross-linker. AlfaBond's chemical sequence allows rapid incorporation into the G3 System slurry and ensures rapid penetration to the chemical clusters on the PolyMud molecule. The cross-linking characteristic of AlfaBond provides the industrys first 'intrinsic-binding' polymer system. In addition, AlfaBond instantaneously bind to soil particles and reinforces the overall stability of the excavation. AlfaBonds main applications include fluid loss control and localized viscosity boosting, besides allowing combinations within the G3 system's product line that helps solving various scenarios in the most demanding soil conditions. Applied in concentrations over 0,5%, increases the solids suspension abilities of the slurry, further allowing for higher density values. For local applications, the product is added directly at the excavation or placed in plastic bags with a weight to sink it, and holes in order to allow the solution to spread to the excavation.

Note- It is not advisable for the pH to exceed values above 12, since it may damage the polymers molecular structure harming its best performance parameters.

2.4 Super DSand Cleaning

A water based product that includes synthetic biodegradable polymers. This product should be 3 added at rates that may vary from 1 to 4 liters per m of slurry to be treated. The addition of this product causes the sudden precipitation of all solid elements suspended on the slurry to the bottom of either tank or excavation. For cleaning and decreasing density and sand content values of bentonite slurries with 3 3 densities ranging 1.000gr/cm e 1.20 gr/cm , the recommended dosage varies from 1 to 2,5 3 liters per m of bentonite slurry. 3 3 With higher density values between 1.30 or 1.40gr/cm , the dosages are 2 to 4 liters per m of bentonite slurry to be treated. As a result, there should be a decrease of the sand content values in the first 15 minutes. The density values should decrease within 30 minutes. Since the sand particles are heavier than the hydrated clay particles, after the application of Super DSand all the sand sediments and compacts at the bottom whilst the clay particles sediment slower. The addition of the product should be made ensuring that the product reaches the full volume to be treated. For best results if done in a tank, the slurry should be agitated using a pump or compressed air. The agitation should remain until the product is evenly distributed by the total volume of slurry to be treated. Normally an agitation by compressed air should not take longer than 5 minutes. When added directly at the excavation the drilling tool ensures the agitation and even displacement of the product in the slurry at the excavation. The product may be added during the excavation and after, using a pump. After proper displacement, waiting times should vary accordingly with density and sand content values, although typically 15 minutes should suffice prior to cleaning the bottom of the excavation.. The bentonite slurry after the application of Super DSand , remains active keeping its characteristics such as maintenance of cake development and thyxotrophic capabilities. The stabilization and integrity of the excavations are not affected by the application of this product. The application of Super DSand does not interfere with the resistance of the concrete or creates porosity.

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3 Technical specifications and key slurry properties to be monitored

3.1 Viscosity The viscosity of PolyMud should be maintained above 60 seconds per quart (API Marsh Funnel) or as advised by GEOs technical team after on site experience is acquired. The products performance may be affected if the viscosity drops below 50 seconds. There are no upper limits concerning high viscosities, although it is not common to exceed 120 seconds. Higher viscosities do not compromise the excavations integrity, performance of the product or its consumption. We advise higher viscosity parameters in some geological formations. Viscosity should be measured using a Marsh Funnel (API), at the tanks, every time that new polymer is added, prior to sending slurry to the excavation, after receiving polymer from the excavation, during and after the pour and before sending slurry to the storage tanks. Viscosity should also be checked at the excavation whenever needed, prior to placing the reinforcement cage and prior to leaving an excavation open overnight or longer periods. 3.2 pH For best performance, PolyMuds pH should always be kept between 11 and 12. Under no circumstance should the pH of the slurry be lower than 7 or above 12, 5. GEO recommends the use of a strong alkaline base such as Sodium or Potassium Hydroxide for adjustment of pH levels. These products are available in the market both in liquid and solid forms. The continuous monitoring of pH values is extremely important since it is the slurrys only protection against chemical or contaminants in general. GEO advises against the usage of Sodium Carbonate as a pH adjuster. Sodium Carbonate causes viscosity drops, is unable to protect the slurry against chemical contaminants, and is not capable of reaching the required pH levels. pH should be continuously monitored to ensure that the slurry is protected against contamination and in best performance conditions. To test the slurry for pH, Tornassol papers with four colors or electronic devices can be used. At the same time, viscosity should be tested as described above.

3.3 Specific weight or Density The specific weight of PolyMud and PolyGel in a fresh mix is 1.00gr/cm . The slurrys 3 parameters usually range between 1.00 e 1.04gr/cm . Whenever lower hydrostatic pressures are encountered, higher densities can be obtained. Density values are adjusted to the needs of each project after on site experience is obtained. Specific gravity should be checked using a mud balance, at the tank farm, after recycling of the slurry or directly at the excavation whenever requested by project specifications. Besides, it is recommended that specific gravity should be monitored prior to placing the reinforcement cage.
3

3.4 Sand Content GEOs specifications in sampling from the bottom of the excavation are usually equal or inferior to 2,0%. The sedimentation of the soil particles in suspension can be rapidly achieved with the addition of MicroBond , available in the G3 system product line. In addiction de de-sanding process is eliminated as well as the necessary equipment. This method saves production time and requires less space and equipment.

Standard Operating Procedures

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Sand content should always be checked prior to placing the reinforcement cage or whenever specified by project.

3.5 Sampling for monitoring and quality control purposes To ensure that the slurrys properties and characteristics are kept accordingly to required specifications, a thorough monitoring of the plant and excavations must be set. The slurry should be tested for viscosity, pH, density and sand content as described above. GEO may supply a record sheet for the monitoring of all data regarding the slurrys conditions upon request. This record shows all the tests to be performed, in an organized table to be filled on site and later filed for record keeping. 3.5.1 Sampling Procedure for Diaphragm Wall The sampler used must be able to retrieve samples from any point of the slurry column. The volume of each sample must be sufficient to perform the following tests: viscosity (Marsh funnel API), density, pH and sand content. The sampler shall retain the fluid preventing its contamination by solid entrainment whilst being extracted from the slurry column. The samples shall be collected from the bottom of the excavation and on a middle column point. On excavated panels longer than 3.4 meters there shall be collected 2 samples from bottom section and one sample from the column middle point. A fourth sample shall be collected after rebar setting. All 4 testing must be done( viscosity, density, pH, sand content).

3.6 Slurry specifications for Diaphragm Wall On the following table we recommend the slurry quality parameters applicable.

Parameters Viscosity Cone Marsh API (s) Density (kg/m3) Sand Content (%) pH

Fresh mix 65-140* 1,00-1,04 11 - 12

Reused slurry 65-140* 1,08 <2% 11 -12

Prior to concrete pour 50-140 1,04 2% 9 12

*For Brackish or salt water mixing slurry viscosity parameter ranges from 55-140s.

Standard Operating Procedures 3.7 Improving the performance of the G3 system

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In order to improve the performance of the G3 system in extreme soil conditions, GEO advises the following stabilizing products that may be purchased by the client. When requested, GEO may recommend local suppliers.

Product description
Sodium Silicate Aluminum Silicate Sodium Hydroxide

Application
Zone stabilizer Catalyst pH adjustment

GEO recommends this system in some projects to ensure soil stabilization in extreme conditions.

The application is made by combining the Sodium Silicate as the zone stabilizer and the Aluminum Silicate as the catalyst. After the zone stabilizer is applied and after a few minutes so it may have time to react the catalyst is added causing an exothermic reaction and the solidification of the affected area. This solidification occurs through the G3 matrix in the walls of the excavation. The quantities applied are insufficient to cause the solidification or jellification of the slurry in the excavation. These products may also be used for fluid loss control with excellent results. The catalyst may also be applied with AlfaBond and Sodium Hydroxide in a stabilization technique developed by GEO called plasticization of the G3 matrix used to stabilize extreme conditions of collapse and fluid loss.

Standard Operating Procedures

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4 Environmental impact
G3 system is synthetic and biodegradable and non pollutant or harmful to the environment. There are several methods for treatment of polymer slurries after usage. The most common is perhaps the treatment with Calcium Hypochlorite and Muriatic Acid. This treatment neutralizes the pH levels, eliminating the system, turning the slurry into residual water. This procedure is applied only once at the end of the project, unless the client decides to re-use the slurry in another project. The Acid is used to neutralize the alkaline pH. This product is available in liquid form in 3 concentrations of 30%. Quantities to be applied vary from 3 to 5 liters per m of slurry. The tanks must be agitated when this product is added. The Calcium Hypochlorite is available in the market in granular form and different concentrations. The ideal concentration for this purpose ranges 60 to 70%. The quantities to be used vary from 3 0,1 to 0,5Kg per m of slurry by adding the product directly to the slurry after neutralizing the pH. The final result is the transformation of the slurry in residue water. The term residue water is used to best describe the sediment fines and soil particles previously in suspension. The product resultant from this treatment can be directly discharged without any danger of contamination, to the environment or sewage systems accordingly to local laws.

5 Disclaimer
The contents of this document and the information provided are given in good faith and are accurate to the best of our knowledge and experience at date of issue. Since GEO cannot predict or control the different conditions in which this information or our products are used, we make no warranty of performance expressed or implied. Typical properties given herein are not specifications. Users of our products are responsible for compliance with government regulations and local laws.

Thank you for your interest in GEO and for the opportunity to assist you on this project.

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