Request a site inspection

Water

Tunnel water ingress controlLeaks and inflow stopped in tunnels, shafts and underground structures.Crack and joint injectionLeaking cracks and joints sealed, and structural cracks bonded, in concrete and masonry.Waterproofing and polyurea liningsPU membranes and polyurea linings for decks, tanks, tunnels and water structures.

Tunnels

Pre- and post-excavation groutingWater cut off and weak ground consolidated ahead of the face; voids closed behind it.Cavity and void fillingVoids above tunnel crowns, behind linings and under slabs filled without loading the support.Tunnel rehabilitationOld and operating tunnels: seepage stopped, ground consolidated and lining repaired, under traffic.

Ground

Track and slab re-levellingSettled ballastless track and slabs lifted back to level by PU injection, on live lines.Permeation and chemical groutingWeak, loose or wet ground strengthened and sealed by resins and gels that fill it without moving it.TAM groutingStaged grouting through sleeve pipes for shafts, foundations and deep excavations.Curtain and consolidation groutingSeepage cut-offs and foundation consolidation for dams, barrages, shafts and structures.Ground investigation and monitoringERT, GPR and MASW surveys, boreholes, lab tests and instruments, before and after treatment.

Rock, slopes and mines

Rock bolting and self-drilling anchorsRock bolts, self-drilling and prestressed anchors for tunnels, portals, slopes and caverns.Slope stabilisationSoil nails, anchors, mesh, drainage and rockfall barriers for slopes above roads, railways and towns.Mine shaft and strata treatmentWater sealed in shafts and declines; weak roof and face strata consolidated with resins and bolts.
All services →Grouts and resins we make →

Railways

RailwaysSettled track, transition zones and wet tunnels on running lines.

Tunnels and metro

Tunnels and metroWater, cavities and weak ground in tunnels, shafts and metro works.

Hydropower and dams

Hydropower and damsSeepage, foundations, tunnels and slopes on hydro projects.

Mining

MiningWater in shafts and declines, and weak strata at faces and in roadways.

Water, ports and highways

Water, ports and highwaysWater tunnels and shafts, micro tunnels, pipelines, manholes and highway slopes.

Heritage and buildings

Heritage and buildingsSettlement, cracks and leaks in heritage structures and buildings in use.
All industries →Projects →
ProjectsTender deskHow we workProductsGuidesCalculatorsAboutContact

Services

Tunnel water ingress controlPre- and post-excavation groutingCavity and void fillingTunnel rehabilitationTrack and slab re-levellingPermeation and chemical groutingTAM groutingCurtain and consolidation groutingRock bolting and self-drilling anchorsSlope stabilisationCrack and joint injectionWaterproofing and polyurea liningsMine shaft and strata treatmentGround investigation and monitoring

Industries

RailwaysTunnels and metroHydropower and damsMiningWater, ports and highwaysHeritage and buildings

Sales

+91 99100 18144WhatsApp +91 99100 18144connect@geoconstech.com

Railways · Tunnels

Parsik tunnel, Thane–Kalyan

The Parsik tunnel is a 1.3 km brick-lined railway tunnel on the Thane–Kalyan main line, built in 1916. One stretch ran with water every monsoon and kept dripping into the winter. We brought it under control with chemical grouting and self-drilling rock bolts, working around live traffic.

Completed
January 2019
Location
Thane–Kalyan section, Mumbai region
Type
Railway tunnel, brick-lined, 1.3 km
Owner
Central Railway
Client
Shree Krishna Construction (SKCE)

CertifiedCompletion and performance certificates, with CIMFR co-certification. Completed 14 January 2019.

57.7 → 33.2Lu

Lugeon value of the rock before and after grouting, as recorded on the client’s certificate.

1916

The year the brick-lined tunnel was built.

  • Seepage in the treated section brought under control.
  • The rock around the arch consolidated with DrucHyd 2C.
  • The track protected from the water that had been corroding it.
A grouting technician on a platform injecting resin into the arch of the Parsik tunnel
SiteInjecting the arch of the Parsik tunnel, between trains. GCPL site photograph.

The problem

A century-old arch, losing to water

A section inside the tunnel took severe seepage through the monsoon, and the water kept dripping at many points until December or January. Age, and heavy encroachment on the hill above, had weakened the arch over the running lines, and rust had started on the rails.

Traffic could not be stopped. The tunnel carries a main line, so every step had to fit around the trains.

Challenges

What made it hard

  • Little working space.
  • Limited working hours between trains.
  • Water coming in continuously.
  • Poor geology behind the lining.
  • High-voltage overhead line along the tunnel.
  • No ventilation duct.

What we did

Survey first, then the chemistry and the geometry

  • Several site surveys mapped the leaks and the condition of the lining before a method was chosen.
  • DrucHyd 2C, our two-component water-reactive polyurethane, was injected through holes in the lining and driven radially into the jointed rock behind it.
  • Self-drilling anchor rock bolts tied the treated zone together.
  • Optical targets on the lining watched for distress and set how much grouting pressure could safely be used.
  • Many tasks were automated so the crew spent as little time on the track as possible. Where leaking zones could not be reached, the drilling was modelled before it began.
Rehabilitating an old masonry railway tunnel under trafficCross section of a brick-lined tunnel. Water seeps through the arch on the left. On the right, holes drilled from inside the tunnel carry two-component PU through the lining into the jointed rock, with self-drilling rock bolts and optical targets on the lining. Trains keep running under the overhead line. 25 kV1234567
  1. Water seeping through the masonry arch, worst in the monsoon.
  2. Brick-lined arch, more than a century old.
  3. Holes drilled from inside the tunnel, through the lining and into the rock behind it.
  4. Two-component PU injected and driven radially into the jointed rock.
  5. Self-drilling anchor rock bolts tie the treated zone together.
  6. Optical targets on the lining show any movement and set how much grouting pressure is safe.
  7. Trains keep running. The work fits between them, under the live overhead line.
Geo Constech
Parsik tunnel · Cross section
Central Railway · Client SKCE
Schematic · Not to scale

Published“Controlling water incursion in Parsik tunnel in Mumbai using chemical grouting of DrucHyd-2C”, Tunnelling Asia 2019, Tunnelling Association of India, Mumbai, February 2019, pp. 155-162. About the paper →

Site photographs

From the site team

Before: a jet of water entering the Parsik tunnel through the lining
Before
After: the same tunnel wall with injection packers in place and the seepage under control
After
A passenger train passing through the Parsik tunnel while water runs onto the track
SiteWater on the track inside the Parsik tunnel before treatment, with a passenger train passing. GCPL site photograph.
The Parsik tunnel lining after grouting, dry, with sealed injection points
SiteThe lining after grouting: injection points sealed and the wall dry. GCPL site photograph.

Services on this job

Methods used

Tunnel rehabilitation

Old and operating tunnels: seepage stopped, ground consolidated and lining repaired, under traffic.

Tunnel water ingress control

Leaks and inflow stopped in tunnels, shafts and underground structures.

Rock bolting and self-drilling anchors

Rock bolts, self-drilling and prestressed anchors for tunnels, portals, slopes and caverns.

CertifiedCompletion and performance certificates, with CIMFR co-certification. Completed 14 January 2019.

More projects

Similar work

Railways · Sangaldan, J&K

T-46 P2, Sangaldan, USBRL

Ballastless track that settled further every monsoon, lifted back to its design profile on a live line, with the ground beneath made stable.

Certified

Railways · Tunnels · Katra, J&K

USBRL tunnels T-1, T-3 and T-5, Katra

Heavy water ingress in Himalayan tunnels, controlled with our resin, grout design and crews: recorded by Northern Railway at up to 2,500 litres per minute.

Client letters

Railways · Tunnels · Arpinchala, J&K

T-49B escape tunnel, Arpinchala, USBRL

Cavities in a Himalayan escape tunnel treated with low-foaming and water-reactive PU resins: one of the two largest chemical grouting jobs we have held.

Subcontract

A similar problem on your site?

An engineer reviews it and replies with the next step. The client documents behind this project are sent on request.

Request a site inspection Request the documents
CallWhatsAppSite inspection