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By Robert B. Bittner

The Sutong Bridge across the lower Yangtze River in China will have, when completed, the longest span (1,088 m) and the highest towers (306 m) of any cable stayed span in the world. The foundations for this record setting span will also be record setting. They are located in water depths exceeding 30 m with maximum flows exceeding 3 m/sec. The soil at the site of the main pylons consists of layers of silty sands and silty clays extending to bed rock at 270 m below river elevation. This paper describes the innovative methods used by the team of foundation designers and constructors to support this record setting bridge at this very challenging site. This paper covers three specific topics related to the foundations of the Sutong Bridge: ? Design and construction of the 131 drilled shaft (2.8/2.5 m diameter and 114/117 m long) under each of the two main pylons, including the post-grouting of all drilled shaft tips. ? Design and construction of the scour protection for the two main pylons, ? Construction methods used to construct the waterline pile caps (113.8 m by 48.1 m by 13.3 m deep) under each pylon.

Jan 1, 2013

By David R. Shields, Michael T. Bracher

"The $330 million (U.S.) Dana-Farber Cancer Institute’s Yawkey Center for Cancer Care (Yawkey Center) sits in the heart of Boston’s Longwood Medical Area. The Yawkey Center is a cutting-edge cancer care facility that houses Dana-Farber’s adult clinical care and clinical research programs. Standing 14 stories above grade, it includes 7 stories of underground parking extending 75 ft (23 m) below ground. The structure is on a 198 by 186 ft (60 by 57 m) site sandwiched between Dana-Farber’s 13-story Richard A. and Susan F. Smith Research Laboratories Building, the Medical Area Total Energy Plant (MATEP), Jimmy Fund Way, and Brookline Avenue, a busy four lane artery through the heart of the Longwood Medical Area. Together with Simon Design Engineering, the project structural engineer, GEI Consultants designed an innovative foundation and excavation support system to isolate the building from ground vibrations generated by the adjacent MATEP power plant. In effect, the Yawkey Center is a 21-story free-standing structure that starts 7 stories below grade.The MATEP facility provides power for 9 million sq ft (840,000 sq m) of occupied space in the medical area. There are six 32-cylinder diesel engine generators in the facility that produce low-frequency ground vibrations in the 10 Hz range, similar to the natural frequency of typical building elements. The resonant response of the Yawkey Center building structure to these ground vibrations would affect the performance of sensitive medical research equipment and cause an unacceptable environment for clinical care.The soil profile at the site consists of stiff clay, fine sand, glacial till, and bedrock consisting of hard metamorphosed conglomerate. In-situ measurements of ground vibrations performed in boreholes showed that there was little attenuation of the vibrations with depth in the soil layers overlying the bedrock, but the vibration amplitude in the bedrock was markedly lower than in the overlying soil. Based on this data, an innovative foundation system was designed to support the building on bedrock located up to 110 ft (34 m) below ground surface, while isolating it from the surrounding soil. This was done by physically separating the below-grade parking garage floors from the perimeter foundation walls to create a free-standing structure supported on the bedrock"

Jan 1, 2012

By Joshua R. Omer

A numerical model is developed for predicting the load transfer and settlement behaviour of vertically loaded, bored cast in-situ piles. Based on analysis of full-scale pile tests, closed-form equations are formulated to uncouple the shaft and base transfer resistance components of the pile/soil system. Appropriate parameters are introduced to take into account: (i) the shaft resistance distribution in unlined and partially lined piles, (ii) the effects of ?soft toe? (voided toe pile) behaviour on base resistance development. For convenience, an interactive computer program has been developed in Matlab? with a user friendly interface system. The program can be applied to predict the complete load-settlement curve and axial force distribution in bored cast in-situ piles if reliable soil test data are available. To demonstrate its validity, the proposed method is applied to 4 test piles, which are also analysed using two previously published methods: (a) elastic solution method and (b) layer discretisation method. Methods (a) and (b) above are based on load transfer (t-z) and finite element models respectively. It is shown that the proposed method yields axial force distributions and load-settlement curves that are in good agreement with the observed pile test data.

Jan 1, 2010

By David Coleman

This paper presents a case history involving the installation of drilled in piles with rock sockets for the Bicycle and Pedestrian Path project located west of the Henry Hudson Parkway within the Riverside Park between 83rd Street and 91st Street at the Hudson River in New York, NY. The paper specifically addresses access and construction procedures for a marine installation when working in an urban and environmentally sensitive setting.

By George Piscsalko

Quality control of drilled shafts and ACIP piles is greatly dependent upon the practices of the site personnel. In many applications it is difficult to properly inspect the shaft prior to concreting, such as when the shaft is drilled under slurry. In other cases, such as ACIP piles, it is impossible to inspect the shaft in any manner prior to concreting. There are numerous methods currently available to assess the integrity of drilled shafts and ACIP piles. Each method has its advantages and limitations. This paper will compare the various available methods as well as introduce a new method for assessing integrity in drilled shafts and ACIP piles. This new method, known as Thermal Integrity Profiling, determines the integrity over 100% of the shaft both inside and outside the reinforcing cage by measuring the hydration temperature of the concrete along the length of the shaft. These temperature measurements can be made by either passing a thermal probe through a standard Cross Hole access tube typically 12 to 48 hours after concrete placement, or from embedding thermal wires within the shaft prior to concrete placement and monitoring them with unattended data collectors for 12 to 48 hours after concrete placement. This Thermal Integrity Profile method will be described in detail and several case histories will be presented. Additional testing methods which will be compared include low strain Pile Integrity Testing, and Cross Hole Sonic Logging. Advantages and limitations for each method will be discussed.

By Juhyung Lee

Numerical analyses were performed to analyze the behavior of two different type of suction piles (mono type and group type) under various soil layer conditions (uniform silty clay layer, uniform silty sand layer, and two-layer deposit consisting of clay and sand layers) and lateral loading locations (top, middle, and bottom of the suction pile). According to the results, mono suction pile shows maximum resistance when load is applied on its middle, regardless of the soil layer conditions, while group suction piles varies significantly according to the allowance on head rotation. When head rotation is allowed, the behavior of group type piles become similar to the behavior of mono suction pile. Whereas, when rotation is prevented, resistance is maximized when load is applied on the top head. Moreover, group suction piles show higher efficiency regardless of the ground condition and geological stratum. For further advances, concrete block on the top of group suction piles are suggested as an effective alternative method to prevent partial rotation and maximize ground resistance for group suction piles.

Volume 1 pages 665-671 Title should read as Dynamic pile testing of H-piles at HDB sites J.Wei, Y. S. Heng, C. S. Lok, M. K.Chong Housing and Development Board, Singapore 'tons' should read as 'tonnes' Para 3.2 fourth equation (page 667) [TC = t2 v.dt t = 0 should read as TC = t2 v.dt - s t = 0]

Jan 1, 1994

By Stephan Fisch, Franz-Werner Gerressen

"The use of cut-off-walls (COW) for the open pit coal mines has been used for decades. They have been used to reduce the negative hydraulic impact to the surrounding area caused by the open pit mining. The pile-guided trench cutting system is a worldwide unique technique, originally developed by the engineers of the mining companies themselves. It guarantees a continuous, joint free, COW during a continuous installation process. At this specific site in Welzow, this technique has been pushed to new limits in order to address the local lake region. Depth capability has been designed to about 430 ft (130m), proven are already depth of about 360 ft (110m) at a constant trench width of 39 inch (1000 mm). This project is approximately. 6.8 miles (11 km) long of COW, scheduled to be completed in 12 years period. About 2.05 miles (3.3km) have been installed, which is equivalent of about 3.5 Million ft² (330,000 m²). The system flushes special clay which forms a filter crust at the inner surface of the trench. Only natural clay resources used, in order to achieve the cut-off effect (colmation effect). The paper explains the installation process of the cut-off-wall as well as the equipment systems developed specifically for this project. After a successful start of the first phase of the project, the next step in the advancement of the equipment is already underway to enable the installation of greater depth to approximately 490 ft (150 m +) and beyond. The next generation equipment system is scheduled to start operation around 2018 INTRODUCTIONThis Serbian saying “Bóh je stworil Lužicu a cert je zaryl brunicu – God created Lusatia and the devil buried brown coal underneath it.” captures local communities’ ambivalence towards lignite.Lusatia is an almost entirely flat stretch of land between the Elbe and Neiße rivers dominated by glacial sands. On the surface, the heathland and woodland is hardly noteworthy. However, three large lignite mining regions, two in Brandenburg and one in Saxony, in the east part of Germany, divert the attention to underground level, down to depths of up to 120 meters. Here, seams crisscross the earth like ribbons. They were formed in the Tertiary around 17 million years ago.The mining of the lignite started almost 200 years ago. To enable open pit mining, a suitable dewatering system was required. At first, wells and drainage system were used. With the increasing demand to go deeper to enable full use of the existing resources with greater mining depth, a decision taken back in the 60th of the last century, the amount of water which had to be pumped increased dramatically. In peak times, approx. 1.57 Billion cubic yards per year (1.2 Billion m³/year) had to be pumped. This led to a lowering of the groundwater level for up to 230 ft (70 m), impacting the regional lake landscape. In order to reduce the influence on the water balance, and bring the water level back to pre1970th, a first development took place to implement the use of specific COW system to depth of about 147 ft (45m)."

Jan 1, 2017

By George Piscsalko

"Quality control of drilled shafts and ACIP piles is greatly dependent upon the practices of the site personnel. In many applications it is difficult to properly inspect the shaft prior to concreting, such as when the shaft is drilled under slurry. In other cases, such as ACIP piles, it is impossible to inspect the shaft in any manner prior to concreting. There are numerous methods currently available to assess the integrity of drilled shafts and ACIP piles. Each method has its advantages and limitations. This paper will compare the various available methods as well as introduce a new method for assessing integrity in drilled shafts and ACIP piles. This new method, known as Thermal Integrity Profiling, determines the integrity over 100% of the shaft both inside and outside the reinforcing cage by measuring the hydration temperature of the concrete along the length of the shaft. These temperature measurements can be made by either passing a thermal probe through a standard Cross Hole access tube typically 12 to 48 hours after concrete placement, or from embedding thermal wires within the shaft prior to concrete placement and monitoring them with unattended data collectors for 12 to 48 hours after concrete placement. This Thermal Integrity Profile method will be described in detail and several case histories will be presented. Additional testing methods which will be compared include low strain Pile Integrity Testing, and Cross Hole Sonic Logging. Advantages and limitations for each method will be discussed.IntroductionDrilled shafts and Augered Cast-in-Place (ACIP) piles have been increasingly used over the past several years due to several reasons including the reduced noise and vibration, speed of installation for ACIP piles, and the large axial and lateral capacities which are attainable for very large drilled shafts. ACIP piles are drilled and cast without any visual inspection. Drilled shafts can be cast in a dry hole which allows for inspection of the hole prior to casting, but the casting process is very difficult to nearly impossible to inspect with any accuracy. Drilled shafts are frequently cast under slurry as a means to stabilize the surrounding soils during the construction process. When casting a drilled shaft under slurry, it is very difficult to accurately inspect the hole prior to casting and it is equally difficult to inspect the shaft during the casting process. Many of the above mentioned processes are blind to inspection and therefore the chances increase for having defects present in the completed elements."

Jan 1, 2017

By Alexandre Alex) J. Bredikhin

"DISCLAIMER: the statements presented herein are those of the author and do not necessarily represent the views of US DoD or its Components.ABSTRACTProgress on the $750M lock project on the Monongahela River was derailed by discovery of large anomalies in the 6.5-7-ft dia. drilled shafts of the new river wall foundation. The anomalies were located 45 to 50’ below the top of the wall at the critical shaft-to-wall interface, and ranged in thickness from several inches to 2-plus feet. A Specialty team, comprised of representatives from the contractor, the Government, and structural design consultants, was formed to evaluate the extent of the problem and the impact on the new lock wall. With no standard method in place, the Government took the lead to develop acceptance criteria for the repairs while the contractor took the lead to identify the repair means and methods. The Government developed a detailed Quality Control plan to capture and document all of the repair data and to approve each shaft repair in a timely manner. This paper provides an overview of the anomalies encountered and the need for repairs; discusses the details of the repair plan; and provides details on the unique quality control measures employed to verify the repairs. By developing and adhering to a detailed quality control plan, the structural integrity of all of the shafts was successfully restored.INTRODUCTIONThe new Charleroi Locks Project is currently under construction by the U.S. Army Corps of Engineers (USACE) in Pittsburgh, Pennsylvania. In the region, the Corps of Engineers is modernizing the series of locks and dams on the Monongahela River. One facet of this modernization is replacement of the existing Locks #4 (aka Charleroi Locks) located upstream of Pittsburgh, Pennsylvania with new and larger capacity locks. The relative location of the project is shown on Fig. 1. The original construction of twin locks (56’x720’ & 56’x360’) and the fixed-crest dam was completed in 1932, with lock walls supported on timber pile foundations. The fixed crest dam was replaced with a gated dam in the 1960’s. The existing lock is undersized and in poor condition and thus needs to be replaced. The project requires the construction of the new river chamber adjacent to the existing land chamber which must remain operational to navigation throughout the construction. In order to accomplish this, the lock walls need to be constructed in the wet. The river wall was constructed using two construction methods referred to on the project as “cofferbox” and “non-cofferbox” construction."

Jan 1, 2017

By Leonhard Weixler, Alexander Blatt, Franz-Werner Gerressen

Diaphragm wall technique is usually used to construct structural elements in the ground, commonly used for retention systems, permanent foundation elements or deep ground-water barriers, named Cut-Off-Walls (COW). It can be anticipated that global urbanization and increasing demands on environmental considerations will need to be accommodated in underground space in the future. These trends show an increasing requirement for diaphragm walling in even more complex conditions, especially in inner-city applications with limited space. Therefore, there is the demand to minimize the size of equipment to accommodate such projects. Following this demand, a new trench cutter system, the so-called CUBE System, was recently developed. The complete trench cutter system has been fit into container size dimensions so that it can work in very limited space conditions. In addition, complex conditions in terms of space limitations require specifically adapted solutions for slurry, spoil, reinforcement and concrete handling and the related logistics to ensure smooth production. Due to the limited space requirements, the impact on the surrounding environment is limited. As the system is electric driven, an additional reduction of carbon footprint can be expected. First tests of the system have been carried out and the results will be shared. The paper will explain the construction process and the specific challenges and experiences made for these extreme conditions.

Oct 1, 2022

By Ashley Shirer

Have you heard a geotechnical engineer rail against using the word "dirt"? The typical maxim is: "It's not dirt, it's soil!" This axiom is so prevalent that it is joked about on the construction site. How did we get to the point in our profession that soil is too technical to understand, while dirt is not viewed as important? Take a moment and think about the images that come to mind by the word soil. Responses range from the sand at a playground to the mud that sticks to the bottom of your shoe, the dark loam found in gardens to the firm earth under your feet. But do you know where the term soil originated? Or how it was intended to be used? This article looks at how word choice can lead to very different motivations for owners, designers and constructors.

May 1, 2023

By James P. Hambleton, Sam A. Stanier

A perceived advantage of screw-type foundations is the ability infer aspects of foundation performance from quantities measured or observed during installation, especially the installation torque. A particular concept widely used in practice is to correlate installation torque to ultimate capacity. This notion has proven useful as a field verification technique despite the absence of validated models that relate key variables of interest, such as installation torque, axial (crowd) force, geometrical parameters, and soil strength. This paper considers previous work by the co-authors and collaborators on analytical, numerical, and physical modelling of screw piles to relate the quantities measured or controlled during installation (e.g., installation torque) to the ultimate capacity and soil strength. Attention is given to saturated clay as a particular soil type amenable to simplified analysis. An analytical model for a single-helix pile is considered as a means of directly relating the ultimate capacity and undrained shear strength to the installation torque, crowd force, plate pitch, plate diameter, shaft diameter, installation depth, and surface roughness. The connection between the installation variables and ultimate capacity—and the sensitivity to crowd force in particular, a quantity that is typically not measured during field installations—is also discussed. The theoretical predictions are compared against data obtained from small-scale laboratory experiments that suggest the installation torque relates to the remolded strength of the soil. INTRODUCTION Screw piles are deep foundations that are twisted into the ground through an applied torque. Advantages over driven piles or drilled foundations include the relative silence of the installation, with low ground vibrations, and the possibility of being easily decommissioned by reversing the direction of twisting. Screw piles are now routinely encountered as a flexible, low-cost solution for numerous applications (Figs. 1 and 2), and they are also being considered for applications in offshore energy production due to limitations being imposed with respect to decommissioning and underwater noise. Also known as “screw anchors,” “helical piles”, or “helical anchors,” screw piles consist of helices or helical plate elements attached to a central shaft. Figure 3a shows the components of a single-helix pile and key variables. The diameters of the shaft and helix are denoted by d and D, respectively, and p is the pitch of the helix. Variable H denotes depth of the helical plate, and T and N denote the torque and axial (crowd) force applied during installation. In typical applications, the pile includes multiple helical plates, and the shaft is composed of segments that allow for it to extend to large depths into the soil.

Jan 1, 2019

By David S. Graham, Joseph D. Bailey, Paul J. Axtell, Michael K. Muchard

"Two instrumented test piles were simultaneously subjected to a static lateral load test by jacking the piles apart. One of the piles was loaded in axial compression via kentledge during the lateral load test. Both piles were constructed in an identical manner. These piles were constructed and tested as part of a construction-phase load test program for a floodwall improvement project along the Missouri River in Kansas City, Kansas. Details of the subsurface conditions, drilled pile construction, instrumentation, and load testing procedures are described. Data collected during testing of the piles are presented and compared. Potential effects of the axial compressive load related to observed differences in pile lateral response are discussed.INTRODUCTIONTwo instrumented test piles were simultaneously subjected to a static lateral load with one of the piles also subject to a combined axial load during testing. The load test program was part of a floodwall improvement project in Kansas City, Kansas. Known as the BPU floodwall, the floodwall runs along the south bank of the Missouri River at a Kansas City Board of Public Utilities power generation and water treatment facility. The project location is shown in Fig. 1.Drilled, 2-ft (610-mm) diameter piles were designated by the designer, the U.S. Army Corps of Engineers (COE), as the foundation type for supporting extended floodwall footings. The drilled piles are fully cased, cast-in-place concrete, reinforced with a steel 12x74 (310x110) H-pile. In order to test soil lateral response and pile structural response under combined loading, the COE required that both a lateral test and combined lateral and axial test pile be constructed and tested. In order to most efficiently test both piles and to allow for simpler comparison, the two piles were simultaneously laterally loaded by jacking the piles apart, applying a maximum lateral load of 195 kips (867 kN). A constant axial load was applied to the combined test pile by kentledge prior to lateral loading and was maintained for the duration of the lateral load test. The total weight of the kentledge was 61.5 kips (274 kN). Fig. 2 shows the test setup."

Jan 1, 2017

By Brian Koch

Michels installed 242 drilled shafts to support the piers for a new basket-handle, true-arch twin bridge across the Mississippi River from Moline, IL to Bettendorf, IA. The installation of the drilled shafts was completed with the simultaneous use of two Liebherr LB36 and one IMT 300 drill rigs. Utilizing barges, 233 drilled shafts were installed in the river. Michels crews also installed 7-ft to 10-ft permanent steel casing into the bedrock, and drilled to depths of 60 feet for each shaft. Despite working in strong currents, freezing temperatures and on rocking barges, Michels crews placed the shafts within 3 inches of plan position. Since the drilled shafts are the key piece in supporting the bridge structure, Michels provided cross-hole sonic logging to verify the integrity and strength of the concrete within the shafts and to add another level of quality control for the owner/customer. Extensive planning took place each day to ensure that tugboats, the linchpin of the project, were being efficiently utilized to shift the barges and materials daily. On any given day, Michels transported five concrete trucks by barge from shore to shaft sites to pour between 40 and 240 cubic yards of concrete. The Michels environmental team was diligent with preparing, discussing and implementing a water treatment plan that was accepted by all state and federal agencies and adhered to strict environmental regulations. Grain hopper barges were rented to control and treat the water that was used in the drilling operations. Another challenge crews ran into was the discovery of caverns when drilling into some parts of the bedrock. Michels worked with the engineer to develop a plan to construct the drilled shafts that encountered the caverns.

Jan 1, 2019

By Tae Hwan Lee, Jun-Shin Lee, Daejin Kwag, Sangchul Bang, Gerard T. Houlahan, Moo Sung Ryu

"Geotechnical engineers have been installing innovative, permanent underwater foundation systems utilizing suction buckets for the offshore industry since the early 1980s (Senpere and Auvergne, 1982). This foundation system has been successfully used on numerous and various types of offshore structures in a wide range of environments. Suction buckets have numerous advantages compared to conventional underwater foundation systems. The more notable advantages include easy installation, large loading capacity, low noise and retrievability. The application of reduced water pressure inside the bucket facilitates the installation of the suction buckets, where a suction pump attached at the top of the bucket can accomplish the entire driving operation. Because of this efficient operation, very large suction buckets can be driven into the seafloor, which eliminates the use of a large number of small piles.In Korea, one of the most economical and reliable renewable energy sources is wind power; however, onshore wind power generation has encountered many problems, such as the lack of favorable sites and public concerns about noise and environmental damage. Consequently, offshore wind power generation has attracted increasing attention due to its abundant potential, high efficiency of grid connection, and availability of easy expansion.In November 2011, the government of Korea announced a national offshore wind power development roadmap, which targeted its offshore wind power generation with the goal of becoming one of the top three nations in the world for offshore wind power generation. Korea Electric Power Corporation Research Institute (KEPRI) is the main research arm of the Korea Electric Power Corporation (KEPCO) and conducts research and development on electricity, power generation, renewable energy and other energy-related matters. KEPRI ultimately provides forefront knowledge and leadership to KEPCO with respect to energy and related areas for its near- and long-term needs. Financial support for the overall project, of which the suction bucket foundation system installed for the pilot phase wind turbine is described below, was provided from the New and Renewable Energy Program of the Korea Institute of Energy Technology Evaluation and Planning funded by the Korean Government Ministry of Trade, Industry and Energy"

Jan 1, 2017

By Tae Hwan Lee, Jun-Shin Lee, Daejin Kwag, Sangchul Bang, Gerard T. Houlahan, Moo Sung Ryu

"Geotechnical engineers have been installing innovative, permanent underwater foundation systems utilizing suction buckets for the offshore industry since the early 1980s (Senpere and Auvergne, 1982). This foundation system has been successfully used on numerous and various types of offshore structures in a wide range of environments. Suction buckets have numerous advantages compared to conventional underwater foundation systems. The more notable advantages include easy installation, large loading capacity, low noise and retrievability. The application of reduced water pressure inside the bucket facilitates the installation of the suction buckets, where a suction pump attached at the top of the bucket can accomplish the entire driving operation. Because of this efficient operation, very large suction buckets can be driven into the seafloor, which eliminates the use of a large number of small piles.In Korea, one of the most economical and reliable renewable energy sources is wind power; however, onshore wind power generation has encountered many problems, such as the lack of favorable sites and public concerns about noise and environmental damage. Consequently, offshore wind power generation has attracted increasing attention due to its abundant potential, high efficiency of grid connection, and availability of easy expansion.In November 2011, the government of Korea announced a national offshore wind power development roadmap, which targeted its offshore wind power generation with the goal of becoming one of the top three nations in the world for offshore wind power generation. Korea Electric Power Corporation Research Institute (KEPRI) is the main research arm of the Korea Electric Power Corporation (KEPCO) and conducts research and development on electricity, power generation, renewable energy and other energy-related matters. KEPRI ultimately provides forefront knowledge and leadership to KEPCO with respect to energy and related areas for its near- and long-term needs. Financial support for the overall project, of which the suction bucket foundation system installed for the pilot phase wind turbine is described below, was provided from the New and Renewable Energy Program of the Korea Institute of Energy Technology Evaluation and Planning funded by the Korean Government Ministry of Trade, Industry and Energy."

Jan 1, 2017

By Tony P. Suckling

This paper presents a case study of a piling contract undertaken at Keble College in Oxford in the year 2001. Unusually, and for the first time in the United Kingdom, piles were successfully constructed containing a network of plastic pipes, which are subsequently to be connected to the heating and cooling system for the new building. The pipes cast in the piles facilitate the transfer and storage of geothermal energy between the structure and the underlying ground mass, allowing the new building to be both heated in winter and cooled in summer economically and in an environmentally friendly way. The philosophy of the geothermal pile technology is presented, together with the modified pile construction techniques employed on the site.

Jan 1, 2002

By Karsten Beekhaus, Sander W. Odijk, Rabea Bahlum, Mazin Adnan, Ayman Abdelh Al Nuaimat, Hassan Farhat

The Arab Potash Company, APC, is one of the 10 largest potash producers of the world. The solar ponds at the Dead Sea, used for the enrichment of the salt content in the brine, are of crucial importance for the first step in the exploitation of the potassium salt. Targeting at the expansion of production in the since over 50 years utilized facilities, the increase of the brine exploitation capacity, reducing the substantial brine seepage losses from the ponds, becomes a crucially required measure. In this context, the remediation measures on the over 11 km long Dyke 1, being a main dyke of the solar ponds system, became inevitable to reduce the brine losses, prevent further development of sinkholes and cavities and hence assuring the stability of the dyke. The highly aggressive environment, the acting hydraulic conditions and the sensitive stratification and nature of the existing ground represented remarkable challenges for the design, as well as its implementation by the construction activities. Royal Haskoning developed a solution addressing the challenges above and targeting at a high sustainability of the executed structure, especially in view of the various geological and hydrological hazards repeatedly occurring in this Dead Sea region, including sinkholes of several meters by diameter and depth. The construction works, consisting of a cut-off wall, with depths reaching down to 31 m, were awarded to Bauer International FZE, a subsidiary of Bauer Spezialtiefbau GmbH. Upon the execution of the first section of 4.2 km length, additional sections were subsequently commissioned, also on further dykes, totaling to about 300,000 m² of cut-off wall. The specific project conditions, such as utilization of cutter technique for the excavation in Halite rock, the stability of open trench exposed to hydrostatic pressure of salt-saturated ground water, resulted in unconventional requirements towards the supporting fluid. The extremely aggressive saline conditions –with a Dead Sea water density of 1.25 tons/m3; one of the world's saltiest water–, were further a decisive factor for the definition of the backfill material concept. Despite its clear advantage for construction of cut-off walls with installed sheet piles, the single-phase system with hardening slurries, fulfilling both functions of excavation support and cut-off wall backfill material, had to be abandoned in favor of the two-phase system, to construct a hybrid cut-off wall made of sheet piles and plastic concrete.

May 1, 2022

By Frank Haehnig, Kurt Kogler

"With a height of 200 m, a crown width of 626 m and a concrete volume of 1.6 million m³, the Kölnbrein Dam in the upper Malta valley in Carinthia / Austria is the largest concrete dam in Austria. Boasting a storage capacity of 200 million m³ with a received water load of 54 MN, this is one of the strongest arch dams in the world.During its construction from 1974 to 1977, the dam was equipped with a comprehensive monitoring system capable of comparing developing deformations and stresses with the design values.With a planned reservoir level of 1,900 m a.s.l. the dam saw the reservoir level of 1,860 m a.s.l. breached in the year 1978. This led to extremely high seepage losses of up to 200 ltr/sec and a rise in the foundation water pressure up to 100% of the dam’s height. These observations were caused by the development of horizontal cracks in the area of the middle dam blocks, between the lowest inspection walkway and the waterside.As a consequence, power plant operations had to significantly be reduced and a number of additional measures were carried out – though these did not lead to the desired sealings.The developer subsequently decided that the dam should undergo a general rehabilitation from 1998 to 1994 in accordance with a concept developed by Professor Lombardi. This concept involved erecting a 50 m high support structure with a concrete volume of 500,000 m³ on the airside of the dam, along with the addition of neoprene bearings to transfer 1.2 million tons of the horizontal load. These measures were able to reduce the deformations in the dam enough so that mostly load-bearing injections into the cracks in the dam’s concrete could successfully be carried out by way of targeted grouting measures using injection resin (RODUR) specifically developed for this purpose.In the years 1998 - 1994, a total of 130,000 m of grouting, monitoring and control drillings were executed, and around 200,000 kg of synthetic resin was injected into the cracks in the dam’s concrete.These measures have ensured the dam‘s uninterrupted operation since 1994. A number of small re- injections were again carried out on the contact surface in the years 2011 and 2012."

Jan 1, 2016