2019-02-14b RWM Workshop 1 Backfill Integrated Project Konrad Backup

Backfill for ILW concepts in Germany
Why and how were they selected?

What do we know about their properties?
Hans-Joachim Engelhardt – BGE TECHNOLOGY GmbH
Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

14.02.2019 1
Milton Hill House, Steventon, Abingdon
Remarks concerning the disposal of radioactive waste in Germany
• All types of radioactive waste are to be disposed of in mines.

There are no surface or near surface disposal facilities operated or planned.
• There is a distinction between non-heat-generating and heat-generating wastes.
• For non-heat generating waste former production sites are used
(Morsleben salt mine, Asse salt mine, Konrad iron ore mine).
• The mining activities resulted in large void volumes and complex structure of the
underground openings.

14.02.2019 2
Morsleben radioactive waste repository
― 2 connected mines:
“Bartensleben Mine” and “Marie Mine”
― Production of Potassium and
Rock Salt from 1913 to 1969
― Total volume of mined
structures: ~ 8.7·106 m3
― Waste emplacement
exclusively in “Bartensleben Mine”
― Waste emplacement started in 1971
and ended in 1998
― 36,800 m3 of waste with activity of < 6·1014 Bq

14.02.2019 3
Morsleben radioactive waste repository
excavated total volume:

8.7 million m3

14.02.2019 4
ERAM – Emplacement areas and waste volume

14.02.2019 5
ERAM – Closure concept: Backfilling and sealing

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Asse II salt mine
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Asse II salt mine
Strömungsbarrieren (seals)
Widerlager (abutments of seals)
Stützender Versatz
(supporting backfill)
Resthohlraumverfüllung
(residual-cavity backfilling)
14.02.2019 8
Konrad iron ore mine
The mine was approved in 2007 as the first repository in

Germany licensed under nuclear law.
The former iron ore mine is currently being converted into a

repository.
Up to 303,000 m3 of radioactive waste with negligible heat

generation will be permanently stored there.
Grubenriss / Map of the mine

14.02.2019 9
Konrad iron ore mine
Grubenriss / Map of the mine
14.02.2019 10
Classification of the backfill in relation to the place
UK we seem to have adopted a convention of :

 local backfill
emplaced to fill the free space between and around waste packages
 peripheral backfill
emplaced in disposal modules,
and the near-field rock or access ways
 mass backfill
bulk material used to backfill the excavated volume apart from the disposal
areas (including the shafts)
 The classification in Germany is based on the location of the seals.

14.02.2019 11
Classification of requirements and objectives
(objectives independent of backfill type and host rock)
Requirements resulting from occupational health and safety.
Requirements resulting from backfilling technology and the conditions in the emplacement chambers (in the mine).
Requirements that result from the integrity of the geological barrier and the protection of the surface
(protection of other mine areas).
Requirements resulting from the possibility of waste package retrieval
Requirements resulting from water protection (environmental protection).
Requirements resulting from radiation protection

(Ordinance on the protection against damage by ionizing radiation, StrlSchV)
Long term stability (Conformity of material properties with requirements over the entire period of function)

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General objectives
General objectives of backfilling are
(1) isolating the waste by forming an extra barrier (local backfill),

(2) providing the underground openings with stability and thus avoiding a collapse of openings
(3) reducing the voids in the repository that can be filled with water or brines,
(4) ensuring a favorable chemical milieu with regard to the overall disposal system,
(5) providing a storage volume for gas generated by corrosion or microbial processes
and consequently limiting gas pressure build-up.
Former production mines are often located closer to rock layers containing ground or formation water.
The host rock of former production mines can be damaged due to rock creep and dilatancy.
(2) + (3) are more important in old mines (former production mines) than in deep geological repositories
individually planned and erected for the long-term disposal of radioactive/toxic waste.

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Protection of the surface
Misalignment (tilting) of buildings

Earth surface subsidence
EN 1992 (Eurocode 2): Settlements are impacts

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Essential work steps
Objectives of backfilling
→ specification of acceptance/performance/safety criteria

→ requirements for the backfill body
→ requirements for the backfilling technique
→ requirements for the backfill material
→ investigation of potential backfill material and backfilling techniques
→ selection of the backfill material and the backfilling technique
→ description of the backfill material (material reports) and the backfilling technique
→ quality assurance (QA) – proof of material properties – proof of performance
→ safety proof

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Proves of safety

14.02.2019 16
Types of backfill materials and backfilling techniques
Dry, powdery and/or granular materials
Pneumatic stowing - The backfilling materials are by means of compressed air.

Slinger backfilling
The backfill material is thrown into the openings with a fast-running centrifugal belt.
Bulk material backfilling
The backfill material is poured by means of large boreholes (slide holes) into the openings or
the backfill material is transported with vehicles into the openings.
Suspensions (Mixtures with solid particles in a fluid, e.g. water)
Hydraulic backfilling with or without binder, e.g. cement

In most cases, the hydraulic materials are pumped through pipelines and drill holes.
The method was developed in the 1940s and has evolved over time to be the most widely used backfill method in the mining industry.
Compared with discontinuous transport methods (tanks or drums), the main advantages of hydraulic placement systems are
the low space requirement, the high reliability, and the transport of the backfill and flushing water in a closed pipeline distribution system.
Better to implement in the case of poor accessibility of the openings and high demands on the degree of backfilling.
Very efficient backfilling techniques.
Very well combinable with a pneumatic transport of the solid raw materials.

14.02.2019 17
Examples of local backfill
Filling the free space between and around waste packages.
 Host rock salt

Crushed salt backfill / granular backfill
 Konrad – sedimentary rocks

hydraulic backfill

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Crushed salt (Asse, ERAM)
Roof fall on the second level of the central part Morsleben

Objective of backfilling
Protection of waste packages
from falling rocks
Requirements
 loose bulk material with low moisture content
(Prevention of corrosion of metals)
 limitation of the grain size
 availability

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Local backfill – Morsleben (ERAM)

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Local backfill – Morsleben (ERAM)

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Local backfill
Morsleben (ERAM)

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Local backfill
Morsleben (ERAM)

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Local backfill
Morsleben (ERAM)

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Local backfill
Asse salt mine

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What do we know about the properties of the salt backfill?
Chemical-mineralogical composition
Grain density, bulk density
Grain size distribution
Grain strength / crushing strengths
Proctor density
Compaction behaviour
Porosity and permeability depending on the degree of compaction

14.02.2019 26
Hydraulic backfill (Konrad mine)

14.02.2019 27
Top view of a backfill segment in the Konrad mine with the backfill pipeline
(Befüllleitung) and the vent pipelines (Entlüftungsleitung, Reserveleitung).
Production of the backfill material takes place underground,
because extracted rocks are to be used as aggregates.
Limestone, marl, claystone, iron ore
In addition, solutions that occur in the mine should be added

to the mixing solution (tap water + salt solutions).
System for mounting six pipelines to the roof.

The U-shaped traverse is fitted with adhesive anchors.

14.02.2019 28
Design of the shotcrete walls at the end of each disposal segment

14.02.2019 29
Hydraulic backfill baterial (Konrad mine)
Storage of waste packages in the chambers of the Konrad mine and backfilling of the chambers
(Abwettersammelstrecke: return air collection drift; Einlagerungskammer: emplacement chamber / storage chamber)
Disposal of the waste packages with a forklift truck, construction of the shotcrete wall, and backfilling of the disposal or backfill segments

14.02.2019 30
Hydraulic backfill baterial (Konrad mine)
The backfill will be transported using drum mixer vehicles (volume 7 m³).
It is planned to backfill per hour the content of three drum mixers to realize a backfill rate of 21 m³/h.
The backfill will be pumped with gunning manipulators (shotcrete gunning vehicles) into the backfill
segments.
Experiments on a scale of 1:10 and 1:25 and rheological calculations show that segments with length of
150 m at maximum can be successfully backfilled.
It was decided to realize a disposal and backfill segment length of 50 m.
The remaining volume of the segments is between 800 m³ and 890 m³ and the time of backfilling will be
between 38 and 42 hours.

14.02.2019 31
High flowability, negligible bleeding, segregation resistance, limited maximum grain size, sufficiently long processing time.
No swelling
Low heat-generation during hardening (avoidance of thermal stresses). Low thermal expansion and contraction.
Low gas threshold pressure
Preferred use of cement as binder (pH value)
Requirements that result from the integrity of the geological barrier and the protection of the surface are of secondary importance.
Low strength

14.02.2019 32
Approval according to § 4 of the health protection mining ordinance
LH (Low Heat) cement + aggregate (excavated, crushed rocks) + water (saline solution) + retarder
CEM III/B 32.5 or 42.5 LH-HS, Normal cement with high sulphate resistance (SR cement) EN 197-1
Aggregate:
The processed product has a fine grain fraction below 0.02 mm (20 μm)
of about 15 to 20% by mass and a maximum grain size of about 5 mm.
Slump-flow test EN 12350-8, > 650 mm.

„Mini-slump“ > 25 cm (cf. DIN 18555-2, EN 1015-3, EN 459-2).
Low strength → high water-cement-ratio = 2.0.

The amount of retarder should amount to about 3% of the amount of cement
and is attributed to the water content.
14.02.2019 33
The water demand of the raw materials, in particular the aggregate, changes.

14.02.2019 34
What do we know about their properties?
Laboratory investigations and mock-up tests show that all requirements are met.
- Pressure loss during the pump process

- Parameters of the Herschel-Bulkley constitutive equation
consistency k, the flow index n, and the yield shear stress τ0
- Results on thixotropy
- Total porosity
- Temperature development, heat capacity → amount of heat
- Chemical analyses of eluates according to DIN 38414-4, EN 12457-4, DIN 19528
- Activity concentration of radionuclides of the nuclide chains U-238sec and Th-232sec
- Results of the investigations for the approval according to § 4 of the health protection mining ordinance

14.02.2019 35
Investigations on the floating of waste packages

14.02.2019 36
Investigations on the floating of waste packages

14.02.2019 37
Investigations on the
floating of waste packages
(steel container)

14.02.2019 38
Peripheral backfill, mass backfill
Host rock salt

 crushed salt
 magnesia binder
 salt concrete
Konrad mine
 cement-based backfill (cf. local backfill)

 granular backfill

14.02.2019 39
Magnesia binder (Asse, ERAM)
The hardening of magnesia binders is based on the reaction of magnesium oxide

and/or magnesium hydroxide with a magnesium chloride solution.
Magnesia binders are pumped through pipelines (hydraulic backfill).

Most of the requirements for Konrad backfill also apply to the magnesia binder
used in the Asse mine and the ERAM.
Higher demands on the strength and the deformability.

Due to the aim of supporting and stabilizing the salt mines,
the compaction capacity is limited.
Compaction capacity: amount of volume reduction due to rock convergence.

14.02.2019 40
Strömungsbarrieren (seals)
High quality backfill/sealing material (including permeability) Complete quality assurance program
- High quality of the drift contour (cavity contour)
Widerlager (abutments of seals)

High quality backfill material - QA program without permeability tests
- High quality of the drift contour (cavity contour)
Stützender Versatz (supporting backfill)

High quality backfill material - QA program without permeability tests
- No cutting of the drift/cavity contour
Resthohlraumverfüllung (residual-cavity backfilling)

Lower quality backfill material (higher compaction allowed) – limited quality assurance program
- No cutting of the drift/cavity contour

14.02.2019 41

14.02.2019 42
Pneumatic pre-mixture transport and

underground production of hydraulic backfill
- Asse mine
Pneumatic transport system

of the dry pre-mixture and silos.
Semi-mobile mixing and pumping plant.

14.02.2019 43

14.02.2019 44

14.02.2019 45
Description of all material properties
required for the proves of backfilling according to the requirements
(to ensure the safety goals).
What do we
know?

14.02.2019 46
Salt concrete (ERAM)
https://mule.sachsen-
anhalt.de/fileadmin/Bibliothek/Politik_und_Verwaltung/MLU/MLU/02_Umwelt/Strahlenschutz/Endlager_Morsleben/lfdnr073_228_00_v01_g228.pdf

14.02.2019 47
Salt concrete (ERAM) – Requirements and objectives
Requirements resulting from occupational health and safety (Health Protection Mining Ordinance).
Requirements that result from the integrity of the geological barrier and the protection of the surface.


14.02.2019 48
Approval according to § 4 of the health protection mining ordinance
Ordinance on the protection against damage by ionizing radiation, StrlSchV

Limit values according to StrlSchV, Appendix XII, part A, point 4a
Requirements resulting from backfilling technology and the conditions in the drifts and chambers (in the mine).
High flowability (> class F4 according to EN 206),

negligible bleeding, segregation resistance, limited maximum grain size (< 20 mm),
sufficiently long processing time, flow angle < 4°
Low heat-generation during hardening (avoidance of thermal stresses).
< 55 K under adiabatic conditions. Use of LH (Low Heat) cement.
Low thermal expansion and contraction (< 4*10-5 K-1).
Young’s modulus > 6,000 MPa.
Uniaxial compressive strength ≥ class C8/10. Uniaxial tensile strength > 0.7 MPa

14.02.2019 49
Two backfill materials were investigated in detail – salt concrete M2 and salt concrete M4
Salt concrete M2
https://mule.sachsen-
anhalt.de/fileadmin/Bibliothek/Politik_und_Verwaltung/MLU/MLU/02_Umwelt/Strahlenschutz/Endlager_Morsleben/lfdnr048_192_00_v01_p192.pdf

14.02.2019 50
Salt concrete (ERAM) – What do we know?
Description of all material properties
required for the proves of backfilling according to the requirements
(to ensure the safety goals).
https://mule.sachsen-anhalt.de/fileadmin/Bibliothek/Politik_und_Verwaltung/MLU/
14.02.2019 51
MLU/02_Umwelt/Strahlenschutz/Endlager_Morsleben/lfdnr048_192_00_v01_p192.pdf
Backfilling measures to avert a danger in the central part
Maximum principal Dilatancy

stresses

14.02.2019 52
 Creep induced failure cannot be excluded
 Stabilization measures are necessary to

guarantee a regular plan–approval
procedure for closure later on
=> Backfilling a number of selected

chambers by salt concrete

14.02.2019 53
Hydraulic backfilling –
Morsleben repository (ERAM)
Mixing plant adjacent to the repository site

(A: silos for the storage of cement and powdery additives,
B: shaft Bartensleben, C: concrete mixer,
D: tank for the storage of mixing solution).

14.02.2019 54
Hydraulic backfilling –
Morsleben repository (ERAM)

14.02.2019 55
Hydraulic backfilling – Morsleben repository (ERAM)
View into a receiver tank of the stationary pumping unit View into a receiver tank of the stationary pumping unit.
A filling level sensor is located on the grid.
14.02.2019 56
Between the years 2003 and 2011 the plant was used to pump almost 1 million m³ of
concrete into the mine openings. The production and backfill rates were about 45 m³/h.
Receiver/storage tanks, double piston pumps, Hydraulic pressure damper.

and hydraulic units.
Engelhardt, H.-J., Kreienmeyer, M., Lerch, C., Müller-Hoeppe, N., Köster, R., Eilers, G. & Preuss, J. (2003) A Constitutive Law of Salt Concrete
used for Closure of a LILW- Repository. Proc. ICEM’03, 9th Int. conf. On Radioactive Waste Management and Environmental Remediation.
Fischer, H.; Bergmann, U.; Engelhardt, H.-J.; Hund, W. & Köster, R. (2004) Stabilization of the Central Part of the Morsleben Repository –
Technical Concept, Requirements, Quality Assurance and Operational Experience. DisTec 2004, Int. Conf. On Rad. Waste Disp., Section 6,
Backfill and Sealing of Repositories, 6 p.

14.02.2019 57
Numerical calculations show

• limited ground surface subsidence
• influence of hydration heat on potential pathways is negligible
• improvement of the geomechanical situation
=> compatibility with the closure concept
• insufficient safety level only for some roofs for a short period of time
during backfilling
Geotechnical surveillance programm

• guarantees occupational safety
• proves effectiveness of the measures
• provides data for further calibration and validation of numerical models

14.02.2019 58
 mass backfill, which is the
bulk material used to backfill the excavated volume apart from the disposal
areas (this would include the shafts)
 gravel
 granular backfill (Konrad)
 salt concrete (salt)

14.02.2019 59
Rockfill – excavated rocks (Konrad mine)
Backfilling of drifts with excavated rocks

14.02.2019 60
Backfilling of drifts with excavated rocks

14.02.2019 61
https://www.mining-technology.com/contractors/drilling/dhms/pressreleases/pressmultipurpose-crawler-diesel-drive/
https://mining-report.de/english/blog/new-multi-purpose-crawler-dh-l2000d-with-diesel-hydraulic-drive/
14.02.2019 62
Granular backfill
Upper abutment
Overlying rock
Sealing element 1:
Clay
Sealing element 2:
Caprock Gravel and asphalt
Filter layers
Rock salt
Sealing element 3:
Gravel and asphalt
1st level
Lower abutment

14.02.2019 63
Granular backfill

14.02.2019 64
Classification of requirements and objectives
Requirements that result from the integrity of the geological barrier and the protection of the surface.


14.02.2019 65
Granular backfill – What do we know?
Results of the investigations according § 4 health protection mining ordinance
Chemical-mineralogical composition
Grain density, bulk density
Grain size distribution
Grain strength / crushing strengths
Proctor density
Compaction behaviour
Porosity and permeability depending on the degree of compaction
Results of eluate investigations

Results of investigations with regard to long term stability (experiments, geochemical simulations)
Results of investigations according to the
Ordinance on the protection against damage by ionizing radiation (StrlSchV)
Activity concentration of radionuclides of the nuclide chains U-238sec and Th-232sec

14.02.2019 66
Granular backfill / gravel
Test of gravel compaction (ERAM)

14.02.2019 67
Granular backfill / gravel
Transport and compaction of the gravel (ERAM)

14.02.2019 68
Granular backfill (Asse, mass backfill) crushed salt

14.02.2019 69

14.02.2019 70
Asse salt mine
Pneumatic emplacement
of crushed salt

14.02.2019 71

14.02.2019 72

14.02.2019 73
Thank you for your attention!
STABILIZATION OF THE CENTRAL PART OF THE MORSLEBEN REPOSITORY (BGZ)

Backfilling of mine cavities with nearly one million cubic meters of salt concrete.
74
74
Asse II salt mine
14.02.2019 75
Asse II salt mine
Ausschnitt des Risswerks 775-m-Sohle,

nach dem der Abbau 1/775 von
1938 bis 1942 mit Salzgrus versetzt wurde
14.02.2019 76
Asse II salt mine
14.02.2019 77
Asse II salt mine
Kernmaterial der Bohrungen IV-4.2eKBrg (Kernmarsch 3, 11,50 – 11,80 m, oben) und IV-4.3f-KBrg (Kernmarsch
10, 13,80 – 14,20 m, unten).
Die Bohrung IV-4.2e-KBrg ist um 12,7° geneigt und die Bohrung IV-4.3f-KBrg um 13,0°.
Beide Bohrungen haben einen Durchmesser von rund 100 mm.
14.02.2019 78

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Backfill for ILW concepts in Germany

Why and how were they selected?

Hans-Joachim Engelhardt – BGE TECHNOLOGY GmbH

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

• All types of radioactive waste are to be disposed of in mines.

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

excavated total volume:

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

The mine was approved in 2007 as the first repository in

The former iron ore mine is currently being converted into a

Up to 303,000 m3 of radioactive waste with negligible heat

Grubenriss / Map of the mine

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

Grubenriss / Map of the mine

UK we seem to have adopted a convention of :

 The classification in Germany is based on the location of the seals.

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

Requirements resulting from the possibility of waste package retrieval

Requirements resulting from water protection (environmental protection).

Requirements resulting from radiation protection

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

General objectives of backfilling are

(1) isolating the waste by forming an extra barrier (local backfill),

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

Misalignment (tilting) of buildings

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

→ specification of acceptance/performance/safety criteria

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

Pneumatic stowing - The backfilling materials are by means of compressed air.

Suspensions (Mixtures with solid particles in a fluid, e.g. water)

Hydraulic backfilling with or without binder, e.g. cement

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

Filling the free space between and around waste packages.

 Host rock salt

 Konrad – sedimentary rocks

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

Roof fall on the second level of the central part Morsleben

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

Local backfill – Morsleben (ERAM)

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

Local backfill – Morsleben (ERAM)

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

Asse salt mine

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

What do we know about the properties of the salt backfill?

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

Limestone, marl, claystone, iron ore

In addition, solutions that occur in the mine should be added

System for mounting six pipelines to the roof.

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

Design of the shotcrete walls at the end of each disposal segment

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

It was decided to realize a disposal and backfill segment length of 50 m.

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

Workshop 1: RWM Backfill Integrated Project: Knowledge Banking Workshop

Approval according to § 4 of the health protection mining ordinance

Slump-flow test EN 12350-8, > 650 mm.