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By Partha Sircar

"For Berth 22 modifications at the Port of Oakland, nearly 600 octagonal 24-inch ‘diameter’ precast-prestressed concrete piles were driven, some piles over 160 feet long. Prior to production pile driving, an indicator/test pile program was performed, which included extensive use of dynamic load testing with (Pile Driving Analyzer (PDA) & CAPWAP analyses. The indicator test-pile program resulted in requiring significantly longer piles than the original design based on subsurface borings. The cause of this discrepancy is investigated in light of the available geotechnical information, soil mechanics principles and standard techniques for pile capacity computations. Several interesting phenomena emerged. These include relatively low resistances offered by crushed rockfill than would conventionally be assumed, non-homogeneity of an apparently uniform formation and the effects of jetting on pile side friction. Also revealing was the significant increase in capacity between 1 and 3 weeks of driving for long piles in clay. Recommendations were developed for pile capacity for future use as “lessons learned”.IntroductionThe foundation for the replaced Berth 22 structure at the Port of Oakland in California involved driving approximately 570, 24-inch octagonal precast prestressed concrete piles. A plan and a section for the pile locations are presented in Figure 1.The ultimate loads on the piles used in the design are presented in Table 1 – the loads are quite heavy.The foundation design was followed by an extensive Indicator Pile Program. The contractors (Manson Construction Co. of Richmond, California) opted to use a Delmag D62-02 diesel hammer (Rated Maximum Energy – 165 kip-feet). Per the project specifications, the same hammer was used for both indicator and production pile driving. The production piles of appropriate lengths were ordered based on thr results of the Indicator Pile Program. A number of interesting results were found from the Indicator Program, which is discussed in this paper."

Jan 1, 2015

By M Muzammil, S. Mukerjee, S. Saran, M. Bharathi

"This paper presents the results of in-situ tests conducted on a set of under-reamed piles in a silty sand deposit. Three piles (i.e. vertical, vertical with one bulb and vertical with two bulbs) of diameter 0.2 m were cast upto a depth of 5 m. The pile cap had four foundation bolts cast into it so that a mechanical oscillatormotor assembly could be mounted centrally on it. The oscillator-motor assembly was used to generate purely sinusoidal dynamic forces, in either horizontal or vertical directions. For both horizontal and vertical vibration cases, it was observed that (i) the natural frequencies decreased with an increase in the excitation force level, (ii) for the same excitation level, the natural frequencies as well as the maximum amplitude of vibration are almost the same irrespective of the pile geometry i.e. number of bulbs in the pile, indicating that the full pile length is not being excited. For the vertical vibration case, the soil-pile stiffness at frequencies, before resonance, were observed to be higher than those at frequencies after resonance. In the horizontal vibration case, the stiffness of the soil-pile system was found to be decreasing with an increase in the excitation force level. The damping ratio was found to be increasing with an increase in the excitation force level.INTRODUCTIONUnder-reamed piles are piles, normally upto a depth of 6 m, with one or more bulbs along the pile stem. These have been used for structures like transmission towers, structures on expansive soils etc. for a very long time, however it is only in the last 30 years that dynamic response of a pile has been studied. Evaluation of dynamic soil-pile interaction is a very complex problem as the conditions and properties of soil are highly variable and unpredictable. Various models and approaches have been suggested by various investigators for evaluating the dynamic soil-pile interaction problem, but most of them are based on the assumptions that the behaviour of soil is linear and the soil surrounding the pile is strongly adhered to it. But in practice, it is not so. The soil surrounding the pile is always somewhat loosened and undergoes some deformation when a sinusoidal load is applied. This causes the soil-pile system to behave nonlinearly.In earlier studies by Novak, (1974), Novak and Aboul-Ella, (1978) etc. a linear elastic behaviour of soil was assumed. This approach was very useful in understanding the mechanism of soil-pile interaction to a large extent. Subsequently various models were suggested like the lumped mass models with nonlinear discrete springs, dashpots and friction elements Matlock et al. (1978), weak cylindrical zone around the pile model Novak and Sheta, (1980), ideal boundary zone model with non-reflective interface, Han and Sabin, (1995) etc. These approximate solutions give an idea about the mechanism of dynamic pile-soil interaction to a large extent. However, in reality both separation and slippage can occur due to the formation of a weak bond at the contact surface between the soil and the pile when a dynamic load is applied. In addition, the soil column adjacent to the pile experiences large deformations under dynamic loads and thus behaves nonlinearly.Some computer aided model studies on the dynamic response of under-reamed piles have been reported, however, very few insitu dynamic tests on under-reamed piles are reported. Dynamic tests on piles were carried out by Novak and Grigg (1976) on small scale single piles and pile groups in the field. Similar field tests on small scale piles were conducted to study the nonlinear behaviour of a single pile and a pile group under strong harmonic excitation by Han and Novak (1988), Han and Vaziri (1992), Burr et al. (1997), Manna and Baidya (2010) etc. The majority of these experimental studies were focussed on the response of the specific pile groups and compared with the results of a single pile. Hence there was a need to study the influence of pile g"

Jan 1, 2015

By Unnikrishnan Nair, Sandeep S. Nikam, Sanjay D. Patil, Prabir C. Basu

"Mumbai Metropolitan Region Development Authority (MMRDA) entrusted to implement Monorail Systems in various parts of Mumbai Metropolitan Region (MMR) with the objective to supplement the present transport system in MMR. The stretch of Monorail is starting from Sant Gadge Maharaj Chowk (SGMC) and extending up to Chembur Railway Station, divided into 2 phases. Construction of Phase 1 (Chembur to Wadala Depot) is complete and Phase 2 (Wadala Depot to SGMC) is under construction.Monorail runs on prestressed girder (guide beam) of span ranging from 20m to 28m supported on pier founded upon group of end bearing piles embedded in rock, pile group ranging from 2-4 piles of diameter 1000mm each.For the purpose of site characterization, geo-technical investigations were carried out along the alignment of Monorail system as mentioned above. These investigations included field and laboratory tests. The subsurface strata mainly consist of silty sand, gravel, underlain by marine clay extending up to stronger basalt rock with volcanic breccia. Overburden consisting of mainly marine clay ranging from 5.5m to 11m at all locations within the influence zone of settlement.The existing rigid pavement along of Sion-Koliwada and Anik-Wadala were constructed about 5 years prior to the construction of Monorail piers. Before laying the rigid pavement, to improve the geotechnical strength of subsoil (mainly marine clay), ground improvement using stone columns was undertaken by MMRDA. In light of limited right of way, the Monorail piers have been constructed in the median portion of the road. The line became operational on February 2014, in few months it was noticed that, in the vicinity of the Monorail piers, along Sion-Koliwada link and Anik-Wadala link, the Road Pavement Quality Concrete (PQC) panels adjacent to the Monorail piers started showing distress in form of nonuniform settlement of the concrete panels.Effect of pile foundation on pavements/PQC slab distress and possible causes of distress were investigated. Initially the distress was thought to be upheaval of monorail pier cap, but further investigations revealed the same to be soil settlement occurring over time. This paper describes the investigation carried out for identifying the cause of this settlement."

Jan 1, 2015

By George Aristorenas, Carlos Englert, Jesús Gómez

"Laboratory test data of strain softening soils exhibit the development of a maximum (peak) shear strength followed by a decrease in the strength with continued straining. The rate of strength loss decreases such that an asymptotic minimum value, known as the residual strength, is approached. This paper presents an investigation of the evolution of strength degradation in excavation supported soils that exhibit strain softening behavior. The paper presents a numerical investigation of excavation support of slicken-sided clay, and results of shear testing on materials with similar strain softening behavior. A strain softening constitutive law is presented that can be used with the finite element computer software Plaxis for analysis of excavation support. A typical design section of a deep excavation support in stiff, fissured clay is presented that illustrates the limitations and conservatism of the residual strength approach for excavation support design. Finally, a discussion is presented on the impact of stiffer walls such as diaphragm walls, compared to less stiff systems such as sheet piles, on the design parameters.INTRODUCTIONIn the Washington, D.C. metropolitan area, the Potomac Formation is generally composed of stiff, fissured clays. Geotechnical engineers often associate the presence of slicken-sided planes within the formation as evidence that the soil cannot develop its peak strength. Although it is unclear how old and continuous these slicken-sided planes are, their occurrence, persistence and orientation appear to be somewhat random. Due to this uncertainty, the design of open cut slopes in these materials is often conservatively performed assuming residual shear strength values. This design approach may be justified for long-term open cuts when there is limited amount of geotechnical information and in view of back stability analyses of past slope failures. Furthermore, the lack of confinement in open cuts allows relatively high shear strains near the surface and toe throughout their existence, which promote mobilization of post-peak strength values and the ensuing progressive failure. Indeed, such behavior has been discussed in the past (Skempton, 1970; Schnabel et. al., 1982; Derrenbacher, 1998). A thorough study by Mesri et. al. (2003) of numerous slope failures concludes that the lower bound strength for stability analysis of non-failed slopes is the fully softened strength, which is intermediate between the peak and residual strengths, but that part of the slip surface may be in a residual condition prior to failure."

Jan 1, 2015

By Jianhua Wang, Jianming Yao, Zhen Meng, Jinjian Chen

"Drilled screw pile is a newly developed displacement pile foundation which has been applied in soft clay for many years. Compared with traditional circular displacement pile, It is characterized by high bearing capacity, small volume and small squeezing effects. For the purpose of investigating the squeezing effects of drilled screw pile, a full scale field monitoring test with two test piles was performed. Detailed soil horizontal displacement and pore pressure measurements were conducted in the vicinity of the two drilled screw piles during penetration and subsequent soil consolidation. It can be concluded that the horizontal displacement of the surrounding soil induced by the installation of a drilled screw pile is mainly in a circular region with a diameter of 3 m (r/D<6), and the compaction effect outside the area can be essentially negligible; The excess pore pressures measured at the same time increase with depth throughout the entire process of consolidation, and its dissipation shows an exponential decay as a function of time.INTRODUCTIONA knowledge of the displacement and stress changes induced in the soil surrounding a pile is very important for evaluating pile performance. Numerous field and laboratory research projects have examined loading conditions, total soil stresses, and excess pore pressures during and following pile installation (Pestana et al., 2002). A relatively comprehensive and detailed review of these experimental works from 1948 to 2002 was presented by Pestana et al. (2002). More recently, Xu et al. (2006) conducted a field experiment to study displacements and stresses in the vicinity of two pipe piles during their installation in a soft lightly overconsolidated clay and compared the field measurements with existing predictive methods. Abdrabbo and Gaaver (2011) collected field observation data from four different construction sites to study soil disturbance during construction of piles using continuous flight auger (CFA). They have found that the disturbed zone of soil by CFA has a conical shape and the excess pore pressure has no appreciable influence on the load capacity of the piles.Drilled screw pile (DS pile) is a kind of vibration-free, cast-in-place concrete pile. Because of the excellent bearing performance, low level of vibration pollution and negligible spoil, as well as its fast construction speed, DS pile has been widely accepted by many engineers around the world. As a new type of drilled displacement pile, the significant installation effects of DS pile on the adjacent soil have not been systematically and integrally investigated yet. Since a proper numerical simulation of the real installation process of DS pile is difficult to achieve, the investigation based on field measurements is necessary. This paper presents a field investigation of the installation effects of two DS piles on surrounding soils. Detailed horizontal soil displacement and pore pressure measurements during pile installation and subsequent soil consolidation have been conducted. Based on the monitoring data, variation of horizontal displacements and dissipation of excess pore pressures with depth and time have been analyzed. What's more, the construction machinery and technology used in DS pile installation are also simply introduced."

Jan 1, 2015

By Tsunenobu Nozaki

"Basically, the “Press-in Piling Method” was invented to eliminate construction nuisances, such as noise and vibration which have been serious unsolved problems for advancing societies over a long time. In the construction industry, piling works have been a major cause of noise and vibration, because most piling methods utilize dynamic load to install piles into the ground. The secret of the Press-in Piling Method is to utilize static loading to install pre-formed piles rather than dynamic load. The piles are hydraulically gripped and jacked into the ground by the special piling rig known as the “Silent Piler”. Therefore, the piles can form a robust and firm foundation, which is another advantage of the Press-in Piling Method.The Press-in Piling Mechanism and Implant Foundations The basis of the Press-in Piling Method is simple. The Pres-in Piling Machine installs a preformed displacement pile into the ground by static jacking force. The reaction for the Press-in Force is generated by gripping previously installed piles, which are called “Reaction Piles”. Due to this, the Press-in Piling Machine can produce a powerful piling force whilst only requiring minimal machine size.With the Press-in Piling Method, as piles are pressed into the ground, they are incorporated with the surrounding soils, which provides a large bearing capacity and passive horizontal resistance. These embedded foundations which are firmly anchored into the ground are known as “Implant Foundations”. Being embedded into the ground, the foundations are resilient and maintain their serviceability even in the worst credible design conditions."

Jan 1, 2015

By S. Pastor, S. Hahn

"As the concept of autonomous haulage systems (AHS) moves from prototypes to production-ready applications, the operating performance of the haul road will become critical to the overall success of autonomy in mining. Deterioration in road performance will require remediation, human intervention and significant, albeit temporary, changes to operating procedures, to accommodate road maintenance. With autonomous trucks comes the opportunity to reduce road formation and operating width. This will, therefore, generate potentially significant reductions in stripping ratios and improvements to mine economics, but only if the design of the road, and its associated deterioration rate, is predictable and manageable, based on the materials used to construct the road and the maintenance interventions to be carried out on the road.This article presents the assessment of a digital photogrammetric approach to the characterization of a mine haul road surfacing, or wearing course material. Design and maintenance parameters for these roads are currently determined partly from physical particle size distribution (PSD) assessments of ‘in-road’ material. However, this approach does not accommodate the need, nor leverage the benefits from, AHS. The digital imaging approach is assessed in this article, using two standard digital analysis software tools, together with in-service mine haul road wearing course samples and images that are analyzed to determine the applicability and reliability of the approach to deliver a real-time assessment of haul road surfacing conditions and thus to identify the road maintenance interventions required to address deterioration.Enhancements in mine road design, construction and management for the past 20 or more years has largely been focused on short-term tactical needs. These improvements have not been matched by advances in the fundamental technologies that underpin mine road design and management and, although the quality of mine roads have probably"

Jan 1, 2015

By G. M. Scamans

In the past ten years there has been considerable penetration of aluminum automotive body sheet (ABS) into automotive structures. The exponential increase in demand is resulting in major investments in heat treatment and finishing capacity across the globe. Line speed and tonnage throughput is limited by the continuous heat treatment (CHT) floater furnace rather than the cleaning and pretreatment section where electrolytic treatments that offer higher line speeds should come into favour and roll coating of pretreatment should predominate. The capacity limiting surface texturing pass will either be eliminated or moved to the finishing line or a dedicated mill. The key to making aluminum both embedded carbon and cost competitive with steel for more and more affordable classes of vehicles lies in recycling of both prompt scrap and, in the longer term, end of life vehicle scrap. For the first time scrap separation technology is available that can compete effectively with hand sorting and can sort aluminum shredded vehicle scrap into wrought and cast alloys and then into individual alloy groups. The challenge is to use more end of life scrap in alloy formulation whilst at the same time extending the property range in terms of both strength and formability.

Jan 1, 2015

By E. Gallestey, D. Groenveld, F. Kolb, M. Rozou

"Recent copper price evolution pushes modern mining industry even harder to achieve highest production with maximum efficiency. Operations are bound by numerous contractual and environmental conditions that bring a high degree of complexity to both the operators controlling the process and the plant managers assessing the circuit’s potential and setting the production goals.Advanced process control (APC) for grinding is one important tool to operate this most energy intense area in an optimal way, finding the optimal trade-offs between highest throughput, energy efficiency and product quality based on variable ore properties, production targets and management priorities.ABB’s state of the art control and optimization software platform enables user to design a controller based on model predictive control (MPC). The paper and the presentation show the technology used and the results achieved through an APC controller installed in a pilot project in Aitik (Boliden SA), Sweden. Furthermore, possibilities to interconnect grinding with other areas as stockpile management and flotation with various interconnected APC controllers will be shown. Finally, an example of the return on investment and the payback times based on the increased throughput and better product quality will be presented.INTRODUCTIONDepending on the ore characteristics and the targeted plant capacity, the design of the grinding circuit may vary significantly. Typically, the circuit consists of several mills (rod, ball, SAG, AG) in series and/or parallel with a number of classifiers and sumps at appropriate locations (see Figure 1).The main goal of the grinding section is to reduce the ore particle size to a level that enables efficient separation between gangue and precious metals in the subsiding processing step. The trade-off between quality and quantity has to be made. At the same time, it is also crucial to execute this process at the lowest possible energy and grinding media consumption."

Jan 1, 2015

By A. Martins, L. Goulart, E. Araujo, R. Batista, A. Costa e Silva

Steel cleanness is of great importance to the performance of almost all steel products. From very clean steel for bearings to long products used in civil construction, processing variables – in special those in steelmaking operations- must be properly balanced to achieve adequate cleanness for the desired performance. With the present complexity of steels as alloy systems, it is not efficient nor appropriate to develop these processes on empirical basis alone. Computational thermodynamics can greatly improve process development to achieve the desired cleanness level at reasonable costs. In this work, examples of these calculations and their applications to real steel processing are presented and discussed. The advantages, limitations and areas in which improvement in these calculations is desired are highlighted and discussed.

Jan 1, 2015

By Hongbo Zhao, Jun Wang, Wenqing Qin, Guanzhou Qiu

Jan 1, 2015

By Giulio R. Altoé, Sergio N. Monteiro, Ygor M. Moraes, Rômulo L. Loyola, Frederico M. Margem, Gabriel O. Glória

The tensile properties of DGEBA/TETA epoxy matrix composites reinforced with different amounts of PALF fibers were evaluated. Composites reinforced with up to 30% in volume of long, continuous and aligned PALF fibers were tested in an Instron machine at room temperature. The fracture was analyzed by SEM. This one revealed a weak fiber/matrix interface, which could be responsible for the performance of some properties. The results showed significant changes in the mechanical properties with the amount of PALF fibers.

Jan 1, 2015

By Cui Wang, Qian Li, Kexin Jiao, Haibin Zuo, Jianliang Zhang

Abstract：A rational cooling water system is the assurance for long campaign life of blast furnace．In the paper, the heat transfer of different furnace period and different furnace condition based on the water quality characteristics were analysed, and the reason of the heat flux over the normal from the hydrodynamics was analysed. The results showed that, the vapour-film and scale existence significantly influenced the hearth heat transfer, which accelerated the brick lining erosion. The water dynamic characteristics of the parallel inner pipe or among the pipes were the main reason for the abnormal heat flux and film boiling. As to the reasonable cooling water flow, the gas film and the scale should be controlled and the energy saving should be considered.

Jan 1, 2015

By Jiang Diao, Xuan Liu, Tao Zhang, Bing Xie

In the present study, the oxidation process of vanadium and chromium bearing hot metal was investigated by using CaO-FetO-SiO2 slags at 1653K in MoSi2 furnace. The results indicated that both the vanadium distribution LV and chromium distribution LCr were of the orders of 2.2~2.4 with the basicity range of 1.32~1.78 and FeO weight percent range of 28%~45%. Both LV and LCr decreased with increasing basicity and decreasing FeO weight percent. The phosphorus distribution LP was of the order of 1.34~1.56. However, LP increased with increasing basicity and decreasing FeO weight percent. The oxidation ratio values of V and Cr in hot metal were above 84% and the values of P were nearly 50%. In other words, it means the addition of CaO in vanadium slag provided a certain ability of dephosphorization along with keeping high oxidation ratios of V and Cr.

Jan 1, 2015

By James C. Sever

The mode of operation of dolomite kilns at a magnesium reduction plant using the Magnatherm process was designed to minimize operation cost and maximize kiln refractory life. Analysis of downstream operation issues shows the quality metric for dolime changed from loss on ignition to specific surface area. This produced a complete change in kiln operation; the net results being major plant productivity increases decrease in operating cost, and increases in both kiln operating costs and reline frequency.

Jan 1, 2015

By Virgil Optasanu, Yvon Lacroute, Eric Lesniewska, Tony Montessin, Pauline Vitry, Eric Bourillot, Cédric Plassard

A general challenge in metallic components is the need for materials research to improve the service lifetime of the structural tanks or tubes subjected to harsh environments or the storage medium for the products. One major problem is the formation of lightest chemical elements bubbles or different chemical association, which can have a significant impact on the mechanical properties and structural stability of materials. The high migration mobility of these light chemical elements in solids presents a challenge for experimental characterization. Here, we present work relating to an original non-destructive, with high spatial resolution, tomographic technique based on Scanning Microwave Microscopy (SMM), which is used to visualize in-depth chemical composition of solid solution of a light chemical element in a metal. The experiments showed the capacity of SMM to detect volume. Measurements realized at different frequencies give access to a tomographic study of the sample.

Jan 1, 2015

By Thomas Niehoff, Yin Qing, Wei Zhongling, Liu Yongguo, Zhang Deliang, Tang Le

The gold ore of Shandong Gold Mining (Xinhui) was a refractory ore, which contained multi metallic sulfides (ZnS and PbS etc.) and carbonaceous. The gold ore concentrate came into leaching process and thickener and zinc replacement to recover gold. In order to improve gold recovery, the GOLDOX™ hydrometallurgy process was studied in Shandong Gold (Xinhui) by bench scale and 6 month plant scale test supported by Linde Gas. It was shown that the process promoted the leaching kinetics and improved gold recovery. The residue grade reduced 0.22 g/t in average after oxygen was applied. This indicates an operating profit increase 850,000 yuan/a in the plant. It was setting a good example for similar gold mine plant and would promote the oxygen application in Chinese gold mining industry.

Jan 1, 2015

By Tengfei Qi, Liqiang Fan, Huiqing Tang

A new method to process the oolitic high phosphorus iron ore for phosphorus removal has been proposed in this research. It is an integration of direct reduction and melting separation with carbon-containing pellets prepared using biomass char. Experiments of direct reduction were preceded using a tubular furnace and three parameters were investigated and they were reduction temperature, biomass char adding ratio(molar ratio of carbon to oxygen） and atmosphere. Results show that the optimum condition is of reduction temperature is 1373 K, biomass adding ratio 0.9, PCO2/PCO 1.0 and reduction time 15~25 min. Under this condition, the reduced briquettes with a metallization of 75.0~80.0 % and a residual carbon content of 0.69~0.11 wt% could be obtained. Subsequent melting separation experiments were conducted using a Si-Mo high temperature furnace. Results show metal with phosphorus content of about 0.4 mass% could be obtained from the reduced sample.

Jan 1, 2015

By Qian Li, Li-chen Hou, Yong-bin Yang, Tao Jiang, Jian-jun Hu, Bing Xu

Extraction of gold from refractory gold concentrates usually requires an oxidation step to remove arsenides、sulphides and carbonaceous matter. In this investigation, the gold concentrates were two-stage roasted under different atmospheres and temperatures. Results indicated that at the first stage, under neutral atmosphere, the removal rate of arsenic increases as the temperature rises. Under the oxidizing atmosphere, with the increase of temperature, arsenic content in the residued calcine increases, in addition, the volatilization of arsenic is also affected by the oxidation of carbon that generated CO, which is advantageous to the decomposition of arsenate decomposition. At the second stage of roasting, it is the higher temperature and stronger oxidizing atmosphere, the faster sulfur and carbon oxidated rate is, but at the same time, the calcine appears the phenomenon of consolidation because of the phase of silicate compounds generate.

Jan 1, 2015

By Shuqiang Guo, Xionggang Lu, Yuyang Bian, Weizhong Ding, Lan Jiang, Kai Tang, Changyuan Lu

For recovery of rare earth elements from the NdFeB based permanent magnet scraps, a high temperature process was used. Permanent magnets scraps were firstly oxidized in air. The optimal oxidation conditions under air are at temperature of 700oC holding for 30min. After the oxidation process, the oxides were reduced by graphite crucible at 1500oC under Ar atmosphere. By this way, the rare earth elements were recovered in the form of oxides, and Fe was separated to the metal phase. Boron distributed in both the rare earth oxides (REO) containing slag and the metal phase. In order to reduce the boron contents in the rare earth oxides, the carbon saturated iron bath and NdFeB added carbon saturated iron bath were used to refine the slag. By this process, the rare earth oxides with a comparatively high purity of 98.2% were gotten.

Jan 1, 2015