Cellular backfill — A Review of Some of the Basics

"The need to fill the void space or annulus created between an excavated tunnel or shaft and the final lining system has long been a requirement in underground construction. Most of those types of voids are created as a result of employing the two pass tunneling lining method. Filling of this void is called backfilling. For many years the materials used as backfill were primarily reinforced and non-reinforced concrete, sanded grout, neat cement grout, or blown-in sand/pea gravel. However, in the past 20 years the use of cellular grouts/cellular concrete as the backfill material has greatly increased. Most cellular grout is made of a mixture of water, Portland cement (with or without the addition of fly ash), a foaming agent and admixtures such as a water-reducer or superplasticizer.It is the authors’ preference to use the term cellular grout as opposed to cellular concrete since by ACI Concrete Terminology an ACI Standard (ACI CT 13), concrete contains aggregates. Normally cellular grout does not contain sand (finite aggregate), but almost never contain course aggregates.The authors believe there are several reasons for this increased use of cellular grout as backfill, such as:• The increase utilization of the various trenchless tunneling methods. Tunnels constructed using trenchless method tend to be smaller in size, excavated diameter or cross sectional area. Making man-entry for placing backfill from inside the secondary liner, utilizing pre-installed grout posts, more difficult if not impossible. It is these workspace restrictions that are the drivers as to when to utilize grout ports installed during the pipe/liner fabrication versus grout delivery pipes installed within the void/annulus space.• The ability of cellular backfills to be pumped and flow longer distances.• The unit weight of cellular grouts can be controlled by mix design and generally can range from 560 Kg/m3 (35 lbs/CF) to 1040 Kg/m3 (65 lbs/CF)."