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By Tom McDonald, Rodney Burke

As mining progresses in the West, the depth of material has increased, making highwall stability a major factor in safety and production. The Jim Bridger Coal Mine has made highwall stability a priority, concentrating on safety as well as increasing and improving production. Overburden depths are increasing dramatically; the geological environment consists of medium to soft material, faulting, water, and current pit alignment not favorable to joint planes. Angle drilling the presplit at 20 degrees became necessary as vertical presplit drilling produced wall failures.

Jan 1, 1997

By Christophe H. Locussol

D.C. United, the professional soccer team located in Washington, D.C., completed a 20,000 seat capacity stadium in July 2018 named Audi Field. The project initially considered a foundation system consisting of roughly 800 prestressed concrete driven piles configured in groups with pile caps. A value engineering alternative proposed in a design-build manner ultimately resulted in the use of 300 single element Auger Cast Piles (ACPs) for the foundation system. The ACPs ranged between 1.5 ft and 4 ft in diameter, were up to 85 ft in length, and were connected through a system of grade beams to accommodate large lateral induced loads. Limitations in conventional analytical methods were encountered during the structural design of the piles due to the complexity of the lateral loading and pile fixity conditions. An innovative approach using advanced finite element modeling that incorporated the framing effects of the grade beams was required to meet the strict movement criteria despite large lateral loads.

By M. Cornelius

Drilled shaft construction through caving soils has historically been an uncertain, risky and costly operation. Uncertain, because the zone of caving may or may not be known, risky because the loss of a shaft is disastrous, and costly because the Contractor, who faces these risks, must include large sums of money in his bid for shaft wall stabilization techniques. This case study will discuss the stabilization techniques that are typically used within the United States, and then present new technologies, born in Europe, that are being utilized in the States by Malcolm Drilling Company today.

Jan 1, 1999

By P J. Jacobs

FORACO is the third-largest global drilling services company, and recently celebrated its 50th anniversary. The company’s historical roots are in French-speaking West Africa, delivering hydrogeological drilling services to resource companies, villages and regional centres. Today, FORACO operates over 300 drill rigs in more than 20 countries.The Asia Pacific region of FORACO runs a fleet of 37 late model drilling rigs servicing the diamond drilling, reverse circulation, coal, coal seam gas and hydro drilling sectors.FORACO Australia has extensive experience delivering large diameter coring (LDC) samples to the resource community. In the past three years, the company has been involved in six 8? coring projects in a variety of geographies and geologies, including iron ore, coal and uranium. FORACO has developed proprietary equipment and techniques to deliver cost-effective LDC samples with outstanding core recovery.The FORACO LDC sampling system is hands free, with mechanised rod and corebarrel handing to minimise the risk of manual handling injuries. Sample volumes are six times PQ (the common industry standard for large core samples), with core recoveries consistently above 96 per cent in extremely difficult formations.Eight inch coring is a conventional coring system suited to hole depths up to 150 m. For deeper applications, FORACO has recently invested over $4 M in a 6? wireline coring system capable of achieving depths of 300 m.CITATION:Jacobs, P J, 2014. Large diameter core sampling, in Proceedings Sampling 2014 , pp 71–76 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 29, 2014

By J. Nakayama

Construction of foundation piles or diaphragm walls through rocky or boulder containing formations has been long-standing difficulty. It has been widely understood that the down-the-hole hammer is the most capable mechanical means but is restricted in drilling diameter by the unavailability of drillhead sufficiently large diameter and the difficulty of disposal of cuttings. A great number of submersible motordrills have been used for the construction of cast-in-place piles and diaphragm walls and the reverse circulation system employed has demonstrated its advantage of the prompt removal of cuttings. The development of multi-head down-the-hole hammer drill combined with reverse circulation system presents a powerful engineering choice for those "hard-to-drill" ground formations. This paper will introduce the features of the system and some actual operation results in the foundation engineering through those hard rocky ground formation in some countries.

Jan 1, 1989

By Chris Normand, Paul Volpe, Eric Wey, Howard Perko, Burt Ogilvie, Patrick Murray

"A refinery expansion project for Marathon Petroleum Company in Southern Louisiana required existing medium to large pipe racks to be expanded for additional capacity. Foundation modifications were necessary in order to add levels to the existing pipe racks. New piles were added and existing pile cap foundations were expanded. Several different pile types were considered. Custom designed large diameter helical piles were chosen, because they can be installed quickly with low overhead restrictions, produce minimal soil spoils, and are cost effective. The load capacity required for piles was higher than typical, off-the-shelf helical piles. In particular, the lateral load capacity demand was high due to wind loads of a hurricane prone region. Methods used to design and size helical piles are summarized including capacity to torque ratio estimation for composite helical piles. Pile load testing was performed in order to confirm design capacities of the helical piles under axial and lateral loading. Measured axial and lateral deflections compared well with predicted values. This case history evaluates the effectiveness of modern helical pile design methods within the context of a real and practical example.INTRODUCTIONAs the capacity of modern installation equipment increases, large-diameter helical piles are being used to support higher loads in more diverse applications. Currently, large-diameter high-capacity helical piles are used for electrical power transmission, power generation, high-rise buildings, bridges, and industrial applications. This case study regards a 2.5-mile pipe rack modification project within an existing refinery. One of the many challenges for engineering and construction of refinery revamp projects is determining how to effectively expand the capacity of existing foundations for additional equipment, piping, and other facilities. Custom designed large-diameter helical piles provided an effective solution to the challenges faced when expanding the capacity of existing pipe racks."

Jan 1, 2017

By W. J. Kingwell

Where the equipment, technique and materials are available for the construction of large diameter rock socketted piles, this is frequently the most economical and environmentally acceptable method of supporting very large concentrated foundation loads in geoglogically appropriate areas. This paper outlines the current approaches in Australia to design and installation of large diameter rock socketted piles. The equipment and procedures described generally reflect those developed or used by Vibro-Pile (Aust.), a company which, while installing the usual range of driven and bored piles, specializes in the design and construction of large diameter rock socketted piles and possesses special expertise in drilling in high strength rock. A high capacity crane attached drill for large diameter drilling in rock is briefly described. Discussed in detail are the construction techniques employed and structural and geomechanical design methods adopted.

Jan 1, 1989

By A. G. Raine

For the technological age in which we live, with the constant goal of further improvement in the efficiency of mechanized systems, the need for a replacement of the antiquated drill and blast method of shaft construction has been recognized. For over a decade now; the trend in shaft construction has been toward large diameter bored shafts using either raise boring methods or more flexible, rodless "down the hole" boring machine. The limits of conventional shaft sinking have been reached, the mining regulations are more stringent, and the environmental agencies more aggressive, all contributing to the growing need for development of the rodless shaft boring machine. In the last three years in the United States, world shaft construction records have been achieved using a V-Mole machine, designed by Mirth GmbH of West Germany, using American electrics and hydraulics. Shafts of 7.0 meters (23 feet) diameter, totaling 2,255 meters (7,400 feet) in depth have been constructed at high advance rates, yet with unusually low accident rates. Bearing in mind the high cost of today's mining labor and the inherent danger associated with conventional shaft sinking, this alternative method of shaft construction achieves a fast, competitive, low manpower requirement, whilst enhancing a safer environment for the labor force. Recent results have proven that program time savings of 50 percent over conventional shaft sinking can be achieved which can be directly translated into improved client cash flow projections and more accurate project budgeting.

Jan 1, 1984

By Patrick J. Hannigan, Frank Rausche, Rozbeh B. Moghaddam

Large diameter open-end pipe piles are increasingly used as deep foundations to support heavy onshore and offshore structures. During the driving process, several factors such as subsurface conditions, hammer type, hammer efficiency, pile type, plug conditions, temporarily increased base resistance, and loss of shaft resistance have direct impact on the driveability of large diameter open-end pipe piles. In a uniform subsurface condition, the unit shaft resistance increases with depth. Consequently, more resistance is accumulated as piles penetrate to greater depths which results in higher driving resistance. However, according to the friction fatigue analysis, the greater the number of shearing cycles occurring on a soil segment along the pile shaft, the greater the reduction of its shear resistance. As a consequence, since upper soil layers are subjected to a greater number of blows than those at greater depths, they have a relatively lower resistance compared to what would be calculated with standard geotechnical analysis methods. As a result of this progressive and nonuniform loss of shaft resistance with driving, blowcounts tend to increase at a lower rate than expected from traditional analyses. This paper discusses one of the approaches to the driveability analysis with the geotechnical friction fatigue consideration. It also shows comparisons between predicted driveability obtained from wave equation analysis and field driving records. All analyses were performed for a 2.134 m (7.0 ft) diameter open-end pipe pile installed at a total depth of 192.90 m (554 ft). Two separate static resistance and wave equation analyses were completed for the case study presented in this paper: 1) Friction Fatigue analysis based on the recommendations of Alm and Hamre (2001), subsequently referred to as the FF model, and 2) Standard Driveability analysis based on soil set- up factors, hereafter referred to as the SD model in this paper. Results from analyses included the shaft resistance distributions compared to the result of the signal matching analyses determined from the pile dynamic measurement. Furthermore, predicted blowcounts were compared to observed blowcounts during the pile driving. The comparison analyses indicated a 54.4 percent resistance loss of the Static Resistance during Driving (SRD) due to the geotechnical friction fatigue corresponding to a 46 percent reduction in total resistance. The analyses also showed that average predicted blowcounts using the friction fatigue were 6.4 percent lower than measured blowcounts, whereas, the standard driveability approach showed 42.1 percent higher blowcounts compared to the blowcounts shown in the driving log values.

Jan 1, 2019

By Saba Mohan

This study presents results based on the Pile Installation Demonstration Project (PIDP) that was conducted as a part of the East Span San Francisco-Oakland Bay Bridge Seismic Safety Project. For the three full-scale pile installations, two different high-energy hydraulic hammers were selected for the installation. However, these hammers may not have sufficient energy to drive these large diameter piles at their ultimate capacity following long-term set-up. Nevertheless, these hammers were selected because, soil plug behavior, the generation of excess pore pressures and remolding of soil during driving were expected to reduce the shaft and end bearing resistance, and therefore reduce the energy required to drive these piles to design penetration. Data collected during continuous installation driving and after a series of re-strikes at different set-up times ranging from 1 to 33 days were used as input data for CAPWAP. These results were used to estimate the soil resistance along the pile length and at the toe of the pile, and the soil pile set-up behavior. Validity of the procedures used to predict the soil resistance to driving and predicted blow counts were verified with the field observed blow counts and the energy that was delivered to the pile. Based on combined CAPWAP analyses, the soil pile set-up with time was estimated and compared with results of other methods currently available in the literature for predicting the soil pile set-up rate.

Jan 1, 2002

By A. B. Desai

The construction of 1144 nos. of piles, each 1.5 m diameter, bored-cast-in-situ type and varying in depths from 6.5 to 23m, has been completed as foundation for 26 piers of 548 m long aqueduct across Orsang river to carry 1128 m3 water of Narmada Main Canal of the Sardar Sarovar Project in Gujarat. These piles are socketed 1.5 m into foundation grade rockmass. The portal system of 44 nos. of piles and pile cap at the top for each pier is analyzed considering the portal fixed at bottom of piles. The borings for pile shaft were done deploying reverse mud circulation rigs and also by conventional chiseling and bailing operations. Besides vertical loading tests and lateral loading test on piles, dynamic tests such as low strain integrity testing on 290 piles and high strain pile testing on 17 piles were also conducted. The results indicated that (a) the settlement/ displacement are much less than the prescribed limits (b) good quality of concrete (c) piles are firmly socketed and (d) piles have adequate structural capacity to withstand the design load.

Jan 1, 1996

By GF Brent, Armstrong L. W

It is recognised that presplitting is a special case in blasting which requires the reduction of conventional explosive pressures in order to avoid excessive rock damage. Two routes to achieving this are the use of reduced density explosives or the practice of decoupling the explosive from the blasthole walls. Applications of two such systems in large diameter, deep blastholes are described. Both systems were tested in presplits alongside sections charged with decks of conventional explosives.

Jan 1, 1998

By Patrick S. Hudd

Traditionally in hard rock mining, large diameter raise boring was thought of as 3.04 metre or 3.66 metre diameter holes 300 metres deep. Mine and ventilation engineers were challenged to design systems either incorporating such holes, or slashing and modifying to suit. Now, 5.49 metre diameter holes up to 1,000 metres deep are being excavated. The ability to pilot and ream such holes not only creates new options for mine engineers in mine ventilation system design, but also creates new opportunities in mine access. By combining holes of this diameter with the ability to accurately drill long pilot holes within the diameter of the pilot hole through the entire length of the hole, borehole hoisting systems are now fully capable of being main production or service accesses for mines. This paper will review the present day capabilities of large diameter raise boring, potential applications for such excavations and some considerations for companies contemplating using large diameter raise boring in their operations

Oct 1, 2010

By P. A. Neill, O&apos

The caisson foundation for Vent Building No. 6, at the southern landfall of Boston's Third Harbor Tunnel, was installed inside an unbraced concrete cofferdam 250 feet in diameter and about 70 feet deep. As a spectacular engineering feat, the cofferdam itself certainly ranks first. However, the foundation work within was no routine caisson job and made its own contribution to the state of the art. Comprised of 5 ft. diameter caissons socketed 10 to 16 feet in sound rock, it posed serious challenges in logistics, space limitations and time, requiring development of unique, purpose-made equipment. The unexpected discovery of significant depths of shattered rock overlying acceptable sound rock, along with other surprises of lesser import, compounded the problems. How these challenges were planned for, met and overcome is the subject of this paper.

Jan 1, 1994

By Charles K. Presley

This paper deals with drilling large diameter shafts for the mining and construction industry with diameters in excess of 3 feet to more than 20 feet in diameter. It discusses appropriate applications of the rotary drill method, linings for large diameter shafts, circulation systems,, and the limitations of the method. Each specific rotary drill method is determined by the geology of the area, the depth to be drilled and the formation fluids encountered. Shaft lining or casing must be improved to result in lighter weight, higher strength and lower cost. All phases of rotary drilling equipment must be improved to drill shafts in excess of 10 feet in diameter. As these goals are reached, more shafts of large diameter will be drilled by the rotary method for the mining and construction industry.

Jan 1, 1967

By D. R. Zeni

Current mine development requires the safe, 'expedient, economical construction of vertical shafts for ventilation and access in diverse ground conditions. Advancements in large diameter shaft drilling have lead to exceptional mechanical refinements of shaft drilling technology. The author traces the history of the equipment and methods employed by the large diameter shaft drilling industry and explores likely paths of future development. A few case histories are cited to illustrate the adaptability of shaft drilling as a versatile tool for advanced worldwide mining operations. Safety, schedules, cost, environmental impact, and capability are discussed to assist the mining engineer in the investigation of feasible projects.

Jan 1, 1994

By Frederic Souche, Andrew R. Klaetsch, Brian Hann, Nick Goodenow

This paper describes support of excavation (SOE) design and construction for three large diameter shafts excavated through glacial soil and controlled blasting in complex sedimentary rock formations. SOE in soil consists of unreinforced secant pile rings designed to resist lateral pressure in circumferential compression, eliminating costly steel core beam reinforcing. Controlled blasting at the shafts, adits, and tunnels in densely populated neighborhoods requires managing risks to the public, buildings, and utilities. Controlled blasting approaches limited adverse impacts to receptors nearby while achieving adequate production and fragmentation. A site-specific observational approach was used to adjust blasting parameters, limiting the impact on local stakeholders while maintaining daily progress and managing overbreak.

Jun 13, 2023

By Paul J. Lewis

Estimation of the axial side shear resistance of drilled shaft rock sockets is directly related to the unconfined compressive strength of the bedrock. Commonly, the mean unconfined compressive strength value is calculated from a range of laboratory test results and is used to estimate the side shear of the bedrock. This paper presents the results from a full scale axial load test performed on an 8.5-feet-diameter drilled shaft rock socket, and compares measured side shear values to estimated values for two different rock strata. Measured side shear values correlated well with the design value calculated for the "strong" rock stratum, but did not correlate well with the design value calculated for the "weak" rock stratum. The mean unconfined compressive strength was used to calculate the side shear in both strata, but review of the laboratory data indicates that this value may not have been appropriate for the weak stratum due to a large variation in the laboratory test results. Also included in this paper is a discussion of the subsurface conditions, the laboratory test results, and the methodology used to design the drilled shaft rock sockets for axial and lateral resistance.

Jan 1, 2005

By Paul J. Lewis

Estimation of the axial side shear resistance of drilled shaft rock sockets is directly related to the unconfined compressive strength of the bedrock. Commonly, the mean unconfined compressive strength value is calculated from a range of laboratory test results and is used to estimate the side shear of the bedrock. This paper presents the results from a full scale axial load test performed on an 8.5-feet-diameter drilled shaft rock socket, and compares measured side shear values to estimated values for two different rock strata. Measured side shear values correlated well with the design value calculated for the ?strong? rock stratum, but did not correlate well with the design value calculated for the ?weak? rock stratum. The mean unconfined compressive strength was used to calculate the side shear in both strata, but review of the laboratory data indicates that this value may not have been appropriate for the weak stratum due to a large variation in the laboratory test results. Also included in this paper is a discussion of the subsurface conditions, the laboratory test results, and the methodology used to design the drilled shaft rock sockets for axial and lateral resistance.

Jan 1, 2013

By A. R. Dover

The Richmond San Rafael Bridge (Figure 1) is a 4.3 mile long major toll bridge span across northern San Francisco Bay. Tutor-Saliba/Koch/Tidewater (TSKT) conducted a comprehensive seismic retrofit, which was at the time Caltrans? largest-ever construction contract at $484 million. The robust foundation retrofit design of 11 bridge piers included the installation of 26 new, large diameter (126 to 162 inch OD, wall thickness 1.5 to 2.25 inches) CIDH and CISS piles, with steel pipe piles installed to tip elevations of Elev. ?140 to -220 ft, in water depths up to 70 feet. The open-ended steel pipe piles had initial sections ranging from 71 to 172 feet long, with full lengths that extended to the bay bottom and then through 100 to 130 feet of marine sediments to top of bedrock. The marine soils of most interest consisted mainly of soft to firm Young Bay Mud (YBM), a silty, moderately-sensitive clay common to SF Bay. A key constructability issue was the prediction of pipe piles ?running? under self weight (198 to 625 kips in air) and pile driving hammer weight (IHC S-500 with total assembly weight of 322 kips). The term "pile running" is used to describe the penetration of the pile into the soil due to the self-weight of the pile only. This issue was critical because 1) there was limited head room under the bridge deck, and 2) if piles run too deep, the pile splicing on several piles would be problematic (the lowest desirable pile top elevation after running was +10 ft). While running measurements are sometimes made during marine/nearshore construction, there is little published data on predicted vs. actual running. This paper discusses the running prediction under self weight for 26 piles, and the methodology used in developing the predictions, which ranged from 15 to 94 ft of penetration below mudline. Pile running was recorded and compared with predicted values. The prediction methodology was quite good, and no significant constructability problems were encountered. The authors ?tweaked? the model to provide a slightly improved prediction method. The paper presents the model, predictions, observations, and discusses important lessons learned.

Jan 1, 2006