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By Remo Grandori

"INTRODUCTIONDouble Shield TBMs were introduced in the market in the early seventies with three main targets:• Increase the TBM performances in term of advance per day thanks to the ability to erect a segmental lining simultaneously with the excavation phase.• Be able to advance through unstable and disturbed rocks under the protection of the shields• Provide a finished tunnel by installing a precast lining as the TBM advance.In 2003 SELI developed the design of the Double Shield Universal (DSU) TBM as an evolution of the original Double Shield TBM design.This new TBM design was targeted to improve: the TBM capability to advance through squeezing/converging rock formations under high cover, the telescopic joint design (allowing by such to operate the machine in double shield mode in very weak rock), the capability of the TBM to investigate and treat the ground around and ahead of the tunnel face.In the same lapse of time Single Shield TBMs, originally utilized for soft ground tunnelling, extended progressively their range of application to mix rocks and finally to hard rock tunnelling with increasing performances.This also thanks to the substantial reduction in the installation time of the segmental lining ring that contributed to minimize the TBM stand by time between two consecutive boring strokes.Today the choice between the two types of TBMs needs to be carefully evaluated project by project since one type of TBM may “prevail” in certain geologies and diameters and vice versa.THE VISHNUGAD PIPALKOTI TUNNELThe Vishnugad Pipalkoti Tunnel is part of the 444 MW Vishnugad Pipalkoti Hydro Electric Project (VPHEP) on Alaknanda river in Uttarakhand (India).The Owner is the Indian electric company “Tehry Hydro Development Corporation” (THDC) and the World Bank finances the project.The Headrace Tunnel total length is 13.4 Km and a section of about 12,3km will be excavated by TBM by SELI Overseas (Italy) in subcontract to HCC (India) the General Contractor for the project. The TBM will be delivered ex workshop in March 2016 and it is foreseen to start boring in the second half of 2016.Figure 1 below shows the location of the project and the following Table 1 summarizes the geometrical characteristics of the TBM tunnel."

Jan 1, 2016

By Keithe J. Merl, Brendan FitzPatrick, Gregg Piazza

Urban and industrial construction projects commonly involve interior work within buildings, warehouses and manufacturing facilities. Renovations of these existing structures must address both structural and geotechnical engineering challenges while also balancing the practicality of implementing solutions within site constraints including limited site access, overhead clearance restrictions, vibration tolerances and uninterrupted facility operations. This paper highlights two projects for an international shipping company where mezzanine level additions within active shipping facilities required construction of new foundations. Construction requirements included low vibration levels, as well as rapid and clean installation to limit impacts on the active shipping operations. The selected system also needed to adjust to both variable ground conditions and differing overhead clearances. This paper describes the installation, design and performance of Ductile Iron Piles used to meet the project challenges. The low vibration, driven pile system offered the ability to work within restricted overhead environments while successfully delivering working compression capacities ranging from 45 to 75 tons (41 to 68 tonnes) as well as lateral and tension resistance. The paper also presents the results of site-specific load testing (and pile capacity) for various termination criteria. INTRODUCTION Urban and industrial construction projects commonly involve interior work within buildings, warehouses and manufacturing facilities. Renovations of these existing structures must address both structural and geotechnical engineering challenges associated with the new construction. Foundation solutions must also balance the need to achieve design requirements with the practicality to be installed within the particular site constraints including limited site access, overhead clearance restrictions, vibration tolerances and uninterrupted facility operations.

Jan 1, 2019

By William Billiet

"The Dulles Silver Line Phase II is an 11.4 mile extension of the Washington Area Metro Transit Authority’s Silver line in northern Virginia. There are three miles of elevated guideway, which are supported on 188 large diameter mono-shafts founded within the Triassic Geologic Aged Culpeper Fault Basin. Three lateral load tests were performed on fully instrumented test shafts. The challenge in developing the load testing program was how to reproduce the effects of the extremely high design loads along the test shafts, considering the limitations of the load test equipment. Development, execution, and analysis of the lateral load test program is discussed.INTRODUCTIONPlans for Dulles Silver Line Phase II include two Aerial Guideway sections on elevated track, the Main Line and Yard Leads. The Aerial Guideways are supported on mono-shafts (single, largediameter drilled shafts) socketed into rock. Lateral loads are resisted primarily through the stiffness of the shaft and the geotechnical resistance of the rock socket. The monoshafts were designed in accordance with AASHTO LRFD 2014. Based on our preliminary analyses, the production mono shafts were expected to consist of 6.5, 7.5, and 8.5 foot diameter drilled shafts with rock socket lengths varying between 8 and 34 feet (averaging 14 feet). Table 1 summarizes the maximum service load combinations for each size production shaft along the aerial guideway alignment.GEOLOGYThe project is located within the Piedmont Province, a major physiographic province on the east coast of the USA extending from Alabama to Pennsylvania. Within the Piedmont, a number of Mesozoic basins formed in rift valleys. Dulles Airport is located in the Culpeper Basin, characterized by a relatively shallow siltstone rock surface compared to the adjacent areas underlain by Piedmont crystalline rocks. The geologic stratigraphy at the load test sites generally consist of residual soils and intermediate geo-material (IGM) overlying siltstone rock. IGM is a term used by Virginia Department of Transportation (VDOT) to describe residual material as it transitions between soil and rock. For the purposes of the load test, the siltstone rock is classified as fractured rock (RQD<50), and competent rock (RQD=50). Table 2 summarizes the stratigraphy encountered at each test site."

Jan 1, 2017

By Thomas Hyatt, Brandon Phetteplace, Camilo Alvarez

A test pile program was undertaken at a project site in Ain Sukhna, Egypt for an import/export oil jetty. Two 1219 mm diameter open ended steel pipe piles were evaluated at two separate test locations. Each test pile was dynamically tested during initial drive utilizing a Pile Driving Analyzer (PDA). Restrike testing was also performed to evaluate the time dependent soil setup. One static compression test and one static tension test was performed at each test location. A correlation of the static and dynamic load test results was established to develop a driving criteria for the piling across the two kilometer project. The constructability benefits of shorter piles will be discussed in more detail, given that the pile lengths were shortened by 9 to 10 meters on average. Lastly, the use of a four pile linear layout to perform both compression and tension tests will be covered. INTRODUCTION With the increased number of Very Large Crude Carriers (VLCC) & Ultra Large Crude Carriers (ULCC) being used to transport oil products around the world, companies and/or nations are presented with the challenge of transferring these products to and from the carriers in deep water scenarios, typically 15 to 20 meter depths, to accommodate the vessels draft. One option for loading/unloading the oil products from a VLCC or ULCC would be to transfer to/from smaller vessels several miles offshore, whereas the most economical option is to unload directly to a pipeline via a berth/jetty platform near shore. These berth platforms must be designed to withstand multiple loading scenarios while these carriers are moored and transferring their products. The use of Large Diameter Open Ended Pipes (LDOEP) piles are a common foundation choice for this offshore application. One of the drawbacks of LDOEP piles, especially across a large project site, is that there can be extreme variability in the pile driving behavior. This can be caused by either a change in soil conditions or the performance of the soil plug. Due to this variability, it is important to verify throughout the duration of the project that the piling is being installed to the correct criteria as established during the load test program. A well designed driven pile load test program, preferably with the combination of Static Load Testing (SLT) and Pile Driving Analysis (PDA), should develop a driving criteria that can allow the contractor and owner to monitor any change in driving behavior.

Jan 1, 2019

By Terrence M. Carroll, Chu E. Ho

"A pile installation and load testing program on driven tapered piles was undertaken at John F. Kennedy International Airport in New York City for the extension of the existing Terminal 4. As part of the program, dynamic testing by means of the Pile Driving Analyzer (PDA) was performed on several preliminary test piles as well as production piles. The results of the dynamic tests and subsequent static load tests were reviewed to develop an understanding of the pile-soil response of a tapered pile during driving and after setup. Pile setup occurred as a result of increase in shaft resistance with virtually no increase in toe resistance. More than 150 tons of additional capacity was gained after the setup time.The capacities measured during driving from the PDA are typically used as the basis for determining the pile driving set criteria, with the required initial driving capacities determined largely by the contractor’s experience. An improved appreciation of the setup phenomenon is required to better refine the driving criteria at the end of initial driving such that the required ultimate capacities can be obtained, with reasonable confidence, after a period of setup.This paper presents interpretation of pile-soil behavior from Case Pile Wave Analysis Program (CAPWAP) analyses and discusses the mechanism of increased capacity as a result of setup effects. Time-dependent capacity gain as a result of setup effects should be based on the extrapolation of the shaft resistance component rather than the total pile capacity as is commonly practiced. Prediction of pile performance using this approach was in good agreement with observed static and dynamic load test results.IntroductionTapered piles have been adopted for various projects at John F. Kennedy International Airport (JFKIA) since the late 1940’s. Initially timber piles were used exclusively, with steel Monotube piles being used from at least the 1980’s (Horvath and Trochalides, 2004). The steel Tapertube pile was developed in the mid-1990’s and has commonly been used in recent construction (Brusey and Yin, 2008). The Tapertube piles used for this project consisted of a 25 foot long tapered section that was 8 inches in diameter at the tip and 18 inches in diameter at the top. An 18 inch diameter straight pipe was welded above the tapered section."

Jan 1, 2015

By Bosco Poon, Kim Chan, Luis Raúl Castañeda, Geoff McKay

"Driven steel tubular piles of up to 2 m diameter have been used to support abutments and piers of a bridge over Nambucca River and floodplain. The bridge was designed by Arup-Aurecon Design Joint Venture (Lead Designers) with GHD leading the geotechnical design assessment in conjunction with Acciona Ferrovial Joint Venture (AFJV – Principal Contractor). Piles were to be driven through alluvium and founded on foliated Phyllite bedrock. The large diameter piles posed significant challenges on bearing capacity assessment and pile acceptance criteria, especially for anisotropic rock strength. Prior to pile driving, boreholes were drilled at each pile location, accompanied with a suite of rock index and UCS testing. AFJV and GHD oversaw geotechnical construction verification. All production piles were monitored with a Pile-Driving-Analyser to manage driving stresses and pile termination. Wave matching CAPWAP analyses were performed on 40% of the piles at the end-ofdrive, or restrike, to satisfy specification requirements and limit over-driving. This paper presents discussions on the design and construction of the driven piles with findings from the extensive dynamic pile data obtained. Based on the shaft resistance distribution and toe resistance obtained from CAPWAP analysis, the mobilised pile shaft frictions fs of the soil / rock materials, as well as the end bearing fb of the founding Phyllite bedrock, are examined. The impact of the rock fabric foliation angle on the m obilised fb, and the relationship between rock strength and the mobilised fs are outlined.INTRODUCTIONThe Bridge over Nambucca River consists of a single bridge structure, comprising single substructures and separate superstructures. The 850 m long bridge facilitates the crossing of the Northbound and Southbound carriageways of the Pacific Highway Upgrade over Nambucca River, with central median barriers, separated by a horizontal clearance of 50 mm. The bridge is required to span over the Nambucca River, which is a navigational channel, and over the adjacent floodplains, including two local access roads and the existing Pacific Highway. The bridge superstructure consists of 21 simply supported spans, each comprises four 2.25 m deep precast post-tensioned U-Girders, with two girders across the width of each carriageway. The spans of girders vary from eleven spans of 39.5m and ten spans of 41.5 m. The floodplain section of the bridge was founded on up to 2m diameter steel tubular piles, designed to be driven through alluvial sediments and weak rock to nominal refusal on sound rock. Dynamic load testing using wave matching CAPWAP (CAse Pile Wave Analysis Program) analyses in conjunction with PDA (Pile Driving Analyser) were used to verify the pile integrity and mobilised capacity. This paper discusses geotechnical aspects associated with design and construction of driven piles. The methodology developed for construction to verify pile capacity and to meet acceptance criteria is outlined. Based on the shaft resistance distribution and toe resistance obtained from CAPWAP analysis, the mobilised pile shaft friction, fs of the soil / rock materials, as well as the end bearing, fb of the founding Phyllite bedrock, are examined. The impact of the rock fabric foliation angle on the mobilised fb, and the relationship between rock strength and the mobilised fs are outlined."

Jan 1, 1900

By Scott Webster

Dynamic pile Monitoring Services (DMS) have been used for testing of offshore piles for several decades. However, most of this testing was to measure hammer performance and pile stresses rather than pile capacity or soil resistance. As the need for more economical solutions for foundation support increases, the use of DMS has provided a better means of evaluating in-place pile capacity for offshore structures, and therefore a method of determining pile acceptance. The authors have been involved in several offshore projects where DMS has been the primary source of data for acceptance of the driven pile foundations. The use of DMS for evaluation of offshore foundations requires considerations quite different from land applications and these considerations are often necessary for the careful and thorough analysis of the collected data in nearly real time for determination of pile acceptance. Case Method capacity estimates are often of little use due to the non-uniform cross sections of the foundation piles and their deep penetrations. Therefore, capacity assessments should be made using CAPWAP which is a signal matching program whose utility and reliability has been proven on thousands of projects every year, both on land and offshore. Depending upon the soil conditions at a given location, capacity assessment after soil setup effects may be necessary. In addition, tension capacity is often critical when pile refusal occurs significantly before the design pile penetration depth. Evaluation of uplift capacity can be accomplished by a CAPWAP analysis, which results in a total capacity prediction and its shaft resistance component. The use of hydraulic hammers for driving of these piles also adds the requirement of controlling hammer energy such that over-stressing of the pile is avoided. The calculation of non-axial stresses such as bending or eccentric stresses may also be involved in order to prevent pile damage.

Jan 1, 2010

By Jonathan G. Cannon

"This paper will describe dynamic pile testing conducted during installation of driven octagonal precast prestressed concrete piles used as the foundation for this bridge. The piles were long and hence spliced. A number of the piles showed damage near the splices and the damage location was near the ground surface so that the damage could be verified using visual inspection. The piles and splice configuration are still in use today without modification. Further WEAP driveability analysis has been conducted which demonstrates the effect of the splice on pile stresses and a likely failure mode. A slight modification is proposed to the splice that should prevent the damage on future projects.INTRODUCTIONThe bridge site is located on the Olympic Way, Route 41, about 20km north of the regional centre of Albury, NSW. For a long distance north of the site the Olympic Way ""shadows"" the main Melbourne to Sydney rail line and is located on the Western side and in close proximity. At the bridge site there was previously a sharp dog-leg in the road and a right angle level crossing with the road changing to the Eastern side of the rail line, eventually joining up with the Hume Highway, which in turn now becomes a ring-road through the eastern outskirts of Albury. The dog-leg and rail crossing had warning signs and bells, speed restrictions and rumble strips to warn approaching motorists to reduce speed. Site distance was exceptionally good.Approximately 2years before construction a group of five ""high spirited"" young men from the local area were driving south on the Olympic Way adjacent to a south-bound train. It is understood they interacted with the train crew for a period of time. Unfortunately the car and train collided at the level crossing and all of the young men were killed. There were outpourings of grief in the local community and a decision was made to replace the level crossing with a road-over-rail bridge.The bridge was highly skewed with two piers and two high level abutments with fill embankments on both approaches.GROUND CONDITIONSThe site is open grazing country with approximately level ground at the site with surrounding low hills. The geology was unremarkable with consistent stiff clays for a considerable depth.The design required driven precast prestressed pile foundations with the piles to be driven to a considerable depth.Hard driving with high tension stresses were evident from the start of driving and a variety of different pre-bore lengths were adopted in an attempt to minimise driving and potential for damage. At the abutments the pile locations were predrilled for at least the full embankment depth.PILESThe piles were 550mm octagonal prestressed concrete with the pier piles being single piece and the longer abutment piles being two-piece with a ""standard"" epoxy glued box splice. Pier piles and the initial length of the abutment piles were 24m. The add-on piece used at the abutments was 12m. Pile concrete was grade 50MPa."

Jan 1, 1900

By Ambarish Ghosh, Rituparna Dey, Indrajit Chowdhury

"In port and harbor facilities, jetties and cargo berth terminals are usually installed on piles that remain partially embedded in soil, while a part of it behaves as columns supporting top deck. Technology in vogue adapts a pseudo static analysis in computer where the top deck including piles are analyzed as an integrated system based on finite element method when the piles are modeled as beam elements, while the soil in which it is embedded is modeled as linear or nonlinear springs. Typical berthing force of the ship is considered as a pseudo static force where the dynamic characteristics of the force is taken into consideration by an equivalent impact factor and little study exists on the actual behavior of these type of piles under the transient shock due to berthing impact. Present paper proposes an analytical solution based on which one can compute the dynamic response of such jetty piles considering shear modulus of soil constant with depth. Considering the solution is analytical in nature no special software is needed and can well be adapted fordesign office practice using generic utility software like MATHCAD, MATLAB etc. that makes theproposed model computationally very efficient.INTRODUCTIONResponse of piles under dynamic load has been an important study in the realms of civil engineering, where significant research has been carried out on its dynamic behavior under harmonic loads like one experienced in a machine foundation or under seismic force.A number of researchers have given solution to this problem like Parmelee et al (1964), Tajimi (1966), Penzien (1970), Novak et al (1974, 1983), Banerjee and Sen (1987), Dobry and Gazetas (1988),Chowdhury and Dasgupta (2008).However, most of these theories are based on piles loaded under harmonic load and valid for long piles where structural failure precedes the soil failure considering the piles are long and flexible."

Jan 1, 2015

By Susan Rafalko, Mike Walker, John Sankey, Sherif Aziz, Alex Potter-Weight, Mary Nodine, Frederic Masse

"After several successful projects on the Garden State Parkway and New Jersey Turnpike for support of single-stage MSE (Mechanically Stabilized Earth) walls using rigid inclusions (Controlled Modulus Columns) as an alternate to two-stage MSE walls and surcharge, the Bass River Bridge Widening project presented additional challenges in terms of soil conditions and height of embankment that created opportunities for the design-build ground improvement contractor and its MSE wall-designing partner to enhance their design and construction methods. The specialist contractor decided, in association with the wall system supplier, to perform an independent large scale instrumented test area on the project to demonstrate the ability of the design techniques to model the behavior of the system, as well as the capacity of the rigid inclusions to provide the necessary bearing capacity and settlement control to allow the construction of the highway without any consolidation period. This paper presents a detailed description of the design of the ground improvement system and MSE wall system, as well as the results and conclusions of the monitoring data gathered on the large scale test program. The combination of rigid inclusion ground improvement technologies, such as the CMC system, together with an MSE wall system allows for the rapid and economical construction of high embankment without waiting for a surcharge and consolidation period or the necessity to use a two-stage wall system. In-depth understanding of the design techniques and advantages of this combination will be provided and should be beneficial for any geotechnical engineer or owner looking for innovative solutions to save both time and cost on their projects.1. IntroductionAs development continues on sites with poor ground conditions throughout the world, conventional MSE walls remain a flexible design solution; however, construction of MSE walls in combination with ground improvement is becoming more frequent where extreme differential and/or total settlement prevail due to soft ground conditions. Various techniques have been used in the past in such conditions (e.g. conventional surcharge, staged construction, or two-stage MSE walls), even though these design solutions have typically involved longer waiting times for settlement to occur. As a result, conventional MSE wall design has been combined with a variety of ground improvement techniques consisting of rigid inclusions for an economical and efficient solution with the potential to accelerate construction and limit long term settlement. For the particular subject of this paper, the specialist contractor (Menard) proposed to use CMCs (Controlled Modulus Columns) to support the highest part of the MSE wall. CMCs are grouted displacement rigid inclusions installed in a grid-like pattern using a displacement auger. Before the CMCs are installed, a working platform may first need to be placed to allow equipment to move around the site depending on the ground conditions. Following the CMC ground improvement, an LTP (Load Transfer Platform) is installed prior to the construction of the MSE wall."

Jan 1, 2015

By M. Hesham El Naggar, Maged A. Abdlrahem

"Hollow bar micropiles have constructional advantages such as: fast and low-noise and low vibration installation process and small installation equipment, which allow access to tight places. In addition, they have efficient load transfer mechanism, which facilitates carrying considerable load in compression and tension. The common practice is to use diameter ratio of drill bit/ hollow bar (Db/Dh) around 2 in their construction, and they are typically designed assuming type B as classified by the Federal Highway Administration (FHWA). In this paper, the performance and capacity of Hollow bar micropile with different (Db/Dh) ratios are investigated. Full-scale micropiles were installed at a site in Ontario, Canada, and were tested in order to evaluate the uplift performance of Hollow bar micropile with different(Db/Dh) ratios. Two micropiles with two different ratios 2.25 and 3 were constructed and tested. The total length of the micropiles was 6m with embedded length of 5.75m. The soil at the site was primarily medium dense to dense sand. The results of the load tests are presented and discussed. It was found that the uplift capacity of the micropile increased by about 19.5% as Db/Dh increased from 2.25 to 3.INTRODUCTIONMicropile is a small diameter, less than 300 mm, drilled and grouted pile and is typically reinforced according to Federal Highway Administration (FHWA, 2005). The technology of micropile was introduced in North America in 1970’s, but the growth in the east coast of United State was intense compared to all other cities around the globe (Bruce and Nicholson, 1989). Nowadays, micropile construction is used extensively worldwide as a viable solution that offers several advantages such as fast installation in low headroom, minimal disturbance to the adjacent structure efficient load transfer due to high grout to ground bond strength. As the method of grouting has major influence on the grout – ground bond strength, FHWA has classified the micropiles into four categories. Type A: the grout is placed under gravity and no pressure is required. Type B: The grout is typically pressurized under a pressure range from 0.5 to 1 MPa as the temporary casing is withdrawn. Type C: the grout is placed in two-step process. First, the grout is poured under gravity only as in Type A. Before the hardening of the grout, similar grout is pressured of at least 1MPa without the use of packer. Type D: Like Type C, it is a two – step process, the grout is placed under gravity as in Type A and sometimes pressurized as in Type B. After hardening of the initial grout, additional grout is pressurized between 2 to 9 MPa through sleeved pipe by using packers, as many times as needed. According to this classification, hollow bar micropile is usually designated as Type B. However, the construction technique is completely different from Type B. Recently; there is a trend to supplement the four types of micropiles by Type E as represent to hollow bar micropile (Timothy et al, 2012). The construction method of hollow bar micropile involves two main stages which can be performed in one–step process: advancing the drilling bit attached to a threaded hollow bar to the required depth; and pressurizing the grout through nozzles of the drill bit."

Jan 1, 2016

By Joseph T. Coe, Alireza Kordjazi, Michael Afanasiev

Cross-hole sonic logging (CSL) is a common quality assurance measure for the evaluation of the structural integrity of drilled shafts. The results of CSL can be supplemented by a set of tomographic images generated by cross-hole tomography (CT). Although the same access tubes, sources and receivers are used in both methods, CT has the advantage of providing a higher quality image of the possible anomalies in drilled shafts. Nevertheless, it has been reported in literature that the CSL and CT miss anomalies with sizes of smaller than 10 percent of the cross sectional area of the drilled shaft. This implies poor resolution despite the high-frequency of the stress waves utilized in these methods. This issue with resolution can be at least partially attributable to the fact that CT relies entirely on the inversion of the first time of arrival and ignores the information embedded in the rest of the recorded traces. This study examines the application of full waveform inversion (FWI) to generate a higher resolution image of the possible defects in drilled shafts from the same data used for cross-hole tomography. FWI is a wave-field method that aims to directly match the recorded traces with traces obtained from a numerical model of the domain. This has the benefit of avoiding the selection of the first time of arrival, along with increasing the resolution of the final image due to extracting more information out of the traces. Through a series of numerical simulations, synthetic traces were generated from a drilled shaft with defects of known mechanical properties, dimensions, and location. These traces were then inverted to evaluate the performance of FWI for structural integrity testing of the drilled shafts. INTRODUCTION The presence of construction defects can compromise the structural integrity of drilled shafts and negatively affect their performance (O’Neil 1991; Sarhan et al. 2002; O’Neil et al. 2003; Poulos 2005). Several non- destructive testing (NDT) methods exist that are currently used for the evaluation of the structural integrity of drilled shafts. Cross-hole sonic logging (CSL), cross-hole sonic tomography (CT), and thermal integrity profiling (TIP) are well-established and documented in the industry and practical manuals (Brown et al. 2010). NDT methods prevent the need for coring and excavation and are relatively fast and cost effective. Successful implementation of these techniques has also been reported in the literature (Branagan et al. 2000; Iskander et al. 2001; Mullin 2010; Johnson 2016).

Jan 1, 2019

By T. Nyakudarika

The Unki Platinum Mines concentrator, employing an MF2 circuit configuration which includes fully-autogenous primary milling of run-of-mine (ROM) ore, was commissioned in November 2010. The project was Anglo American Platinum?s first PGM concentrator in Zimbabwe and would form a significant contribution to the group?s platinum production. The project financials demonstrated that the project was operating-cost sensitive. After reviewing the metallurgical testwork, mineralogical examinations, and the history of similar operations, it became apparent that the Unki ore characteristics rendered it amenable to autogenous milling. The primary ball mill, structurally designed for 30 per cent steel load, could be operated at the required initial phase throughput with fully-autogenous primary milling, realizing savings in both power requirements and grinding media consumption. The original mill sizing had been done with fully-autogenous milling in mind, but allowing for flexibility and mitigation in case of varied mining fragmentation. Since attaining steady state, target grinds have been achieved. This paper looks at the Unki ore characterization programme, design considerations, and the operational and control philosophy for a successful comminution circuit, and discusses the design to produce a flexible, low opex, mitigated comminution and overall MF2 flowsheet that is easily expanded in line with the potential for optimum exploitation of the orebody.

Jan 1, 2012

By Jeffrey C. Schuh, Logan Bloemer, Daniel P. Dietzler

Over the past 30 years, the authors have encountered numerous projects where recognizing the geology, soil properties and groundwater conditions, and considering alternative construction techniques have promoted efficient and cost-saving construction. The construction documents for these projects, produced by various engineering firms, provided basic information on geotechnical conditions. The authors became involved in each project either because there was a problem during design or construction or, as a contractor, won the project because they saw a value engineering opportunity to take advantage of the geologic setting of the project to design and build alternatives to what the designer depicted. Understanding the geologic setting is critical before planning and designing begins. Being able to work with the geology and the materials on site is preferred before specifying more costly and complex solutions, which often require the importing of materials and adherence to unnecessary and/or inappropriate specifications. Failing to understand the geology or not knowing all the techniques available for construction can lead designers to develop solutions that could be inappropriate. This paper presents several examples of value engineering and project performance enhancements developed through knowledge of basic soil mechanics and implementing innovative solutions. History and Background Most people attend DFI meetings, present their experiences, listen to others, and read articles and papers with the hope they can learn from others. Geotechnical engineers and contractors often interface with others in the execution of projects who have, at best, a rudimentary knowledge of geology and soil mechanics. Of course, there is a need for architects, bankers, and regulators, etc., but they typically do not have much interest in the nuances of geotechnical engineering, which relies on both art and science. Thus, significant time is spent educating counterparts in the need for comprehensive subsurface investigation programs and the intricacies of construction in the “dirt,” as they typically refer to soil and rock.

Jan 1, 2019

By Serhan Guner, Sundar Chiluwal

Although significant research has been conducted on helical piles, there is a lack of research and official design provisions on the helical pile-to-pile cap connections. These connections may govern the global response of pile cap systems—especially in tall and light structures where uplift forces dominate the response. To improve future industry practice, the objective of this study is to understand the influence of pile-to-pile cap connections on the global behavior of concrete pile caps and develop recommendations for their efficient design. For this purpose, 108 high- fidelity nonlinear finite element simulations are conducted to quantify the influences of bracket type, embedment depths, longitudinal reinforcement percentages, shear span-to-depth ratios, and loading conditions on the load, deformation, cracking, and failure behavior of concrete pile caps. The results indicate that the design configurations involving single bracket type may result in premature concrete cracking around the anchorage zones with a 25% reduction in the uplift load capacity. The investigations also confirm that high reinforcement percentages and low shear span-to-depth ratios result in higher load resistance in all bracket types, and that the load capacities of the double and studded bracket types are similar. For applications requiring the use of lower embedment depths, it is recommended that either double or studded bracket types be used. The research findings have applicability to both helical and micro piles given that both include similar connection types. INTRODUCTION Tall and light structures may experience significant uplift forces at their foundations due to large overturning moments from wind or other lateral loads. Helical piles (e.g., Fig. 1a) can provide a cost- effective, practical, and resilient solution for resisting significant uplift forces. In order to realize the full potential of helical piles, it is imperative that the helical pile-to-pile cap connections (see Figs. 1b, c and d for examples) are properly designed to resist the applied forces. However, there is a lack of research and associated knowledge on the influence of pile-to-pile cap connection detailing on the global response of pile caps.

Jan 1, 2019

By Ahmed Elmekati, Frederick C. Rhyner, Steven R. Lowe

"The current phase of the Pacific Park development (formerly, Atlantic Yards) in Brooklyn involves constructing buildings on a platform over an existing LIRR rail yard. To preserve the maximum amount of space in the already congested yard and protect the yard which remains in service during construction, high capacity foundations are being designed well above previous capacities in the area. In addition to spread footings and small mats, various diameters of drilled piles are being used at design capacities ranging up to 600 tons. The piles are generally grouted at low pressure, up to about 50 psi. Load tests for various drilled elements, including piles, tiedowns and soil anchors, have confirmed allowable side resistance (bond) stresses in dense sand ranging from 20 to 30 psi. Testing with different rigs and operators has shown that down-the-hole hammers are feasible, but the installation techniques, types of equipment and size of the pile make a significant difference. The results show that more cost-effective foundations are possible when ample testing confirms expectations.I INTRODUCTIONThe Long Island Rail Road has operated a mainline on Atlantic Avenue since the 1800s, with a terminal at the intersection of Atlantic and Flatbush Avenues. In the early 1900s, the mainline was reconstructed in a cut and cover tunnel section. The LIRR’s Atlantic Yard was constructed circa 1908 to service the terminal. It was depressed about 25 feet below street grade to coincide with the LIRR’s mainline tunnel under Atlantic Avenue. Record drawings indicate that the gravity retaining walls lining the perimeter of the yard and other ancillary structures had been designed for an allowable bearing pressure of five tons per square foot (tsf). Perhaps by coincidence, the mat foundation for the tower of the Williamsburg Savings Bank was also designed for five tsf in 1929.Figure 1 shows a typical geologic section through the site. The geology and subsurface conditions in this part of Brooklyn consist of fill generally five to 20 feet deep underlain by dense to very dense sand and gravel; in places, with numerous cobbles and boulders which make pile installation challenging. The sand strata that are on the order of 150 to 200 feet thick were laid down by glaciers during the last ice age and have been heavily precompressed. The sand strata are underlain in places by remnants of the Cretaceous-era Raritan Clay formation and Fordham Gneiss bedrock. Because of this, the sand strata generally provide excellent support for shallow foundations and the allowable bearing of five tons per square foot is usually easily justified."

Jan 1, 2016

By Mohamed A. Mansour, Ahmed M. Soliman, M. H. El-Naggar

"Grouted helical piles allow significant increase in pile capacity with low additional cost over that of conventional helical piles. They can be particularly advantageous in sites where installation disturbance can reduce or even eliminate the pile shaft resistance. For helical piles with slender shafts, a grout column offers increased buckling resistance under compression loading, and may reduce the potential settlement required to mobilize the bearing component of their plates. This paper investigates the performance of grouted helical piles installed in loose sand. Grouted helical piles were constructed and tested in a controlled laboratory environment. Helical piles with hollow pipe shaft and single helix were grouted during installation. The grout was injected into the soil under high pressure through two nozzles placed above the piles helices. The load test results showed significant improvement in the performance and load carrying capacity of the helical pile due to the formation of a cylindrical grout column along the entire shaft leading to a higher shaft resistance contribution to the total pile capacity. The results suggest that grouted helical piles with slender hollow shaft could be used to support large structural loads. INTRODUCTIONHelical piles are widely used as a deep foundation system for different engineering applications. They represent an attractive foundation option because of their cost effectiveness, ease of installation even in limited access areas, low levels of noise and vibrations, and their ability to be installed through ground water without casing. In addition, they allow immediate loading upon installation. Helical piles are installed into the ground by applying a mechanical torque to the pile head. The installation torque monitoring provides a kind of quality control during the construction of helical piles. It could be used in predicting the ultimate pile capacity using several capacity-torque correlations (Livneh and Elnaggar 2008; and Hoyt and Clemence 1989).However, helical piles installation can cause soil disturbance within the annular zone affected by the pile helices. This disturbance can introduce fissures within the pile cylindrical failure surface (Vesic 1971; Mooney el al. 1985; and Zhang 1999). Thus, the shear strength of the soil decreases along the affected zone. Bagheri and El Naggar (2013) evaluated the installation effects of helical piles in sand. They reported that as the helical blade proceeds into the ground, sand within the cylindrical path circumscribed by the helices experiences torsional and vertical shearing accompanied by sand displacement and stress changes. This process is more pronounced in the case of multi-helices and large diameter anchors. Bagheri and El Naggar (2016) evaluated the installation effects of helical piles in structured clay. They indicated that the behavior of the helical pile and its capacity are significantly affected by the degree of soil de-structuring induced by the penetration of the pile shaft and helices. In addition to the installation disturbance, helical piles have other drawbacks including; high potential settlement required to fully mobilize the bearing component of their plates, low buckling resistance of their slender shafts, and the incomplete rigidity of the coupling joints along the pile shaft that allow some lateral movement under compression loading (Vickars and Clemence 2000)."

Jan 1, 2016

By Lawrence F. Johnsen, Felix Ferrer, Dino Tomasetti, Cassandra A. Wetzel

"A 17 story building was constructed at the Brooklyn Navy Yard on a site with a long history of development. Most recently the site supported a dewatering well and craneway to service two adjacent drydocks. The subsurface conditions generally consist of the following strata and approximate depths: miscellaneous fill and debris to 20 ft., organic soils to 35 ft., liquefiable sand to 45 ft., varved clay to 65 ft., glacial till to 95 ft. and gneiss bedrock.Hollow core bar piles replaced 18 in. diameter caissons on a 1.67:1 basis. The resulting service loads on the hollow bar piles were 600 kips compression, 21 kips lateral, 180 kips tension and 450 inch-kips moment. The top 30 feet of the hollow bar was cased with a 16 in. x 0.375 in. Grade 50 steel pipe. The piles were socketed 6 feet into bedrock. An extensive load testing program confirmed the axial and lateral load capacities. The paper will also discuss some adjustments to the installation procedure based on the load test program.PROJECTThe hollow bar piles were installed to support a 95,000 sf footprint, 17-story office building at the Brooklyn Navy Yard. The Brooklyn Navy Yard was first developed in the late 1700’s to build merchant vessels. The federal government purchased the old docks and adjoining 40 acres in 1801. The site was an active U. S. Naval Shipyard from 1806 to its decommissioning in 1966. At its peak in World War II it employed 70,000 people, 24 hours a day. Since 1966 the property has been converted to private manufacturing and commercial activity.The site is located between Dry Docks 2 and 3. The adjacent drydocks extend 40 to 43 feet below grade. The drydock walls are restrained by tierods extending back to deadman anchors. The site is also underlain by piles that were installed to support rail lines and a craneway. The building footprint also covered an 85 ft. wide, 70 ft. deep dewatering well which had a thick slab. The structural engineer for the project, ARUP, designed the building to span over the dewatering well.SUBSURFACE CONDITIONSIn September 2014, Langan Engineering conducted a geotechnical engineering study for the project. Figure 1 provides a subsurface profile through the long axis of the site. The general soil profile was very erratic but generally consisted of miscellaneous fill and debris to 20 ft., organic soils to 35 ft., liquefiable sand to 45 ft., varved clay to 65 ft., glacial till to 95 ft. and gneiss bedrock. The fill contained numerous obstructions from the over 200 years of site development. The organic soils were mostly very weak and compressible organic silt. The depths and thicknesses of the varved clay, and sand varied"

Jan 1, 2017

By Isabella Lancellotti, Fabrizio Passarini, Luisa Barbieri, Fernanda Andreola, Ivano Vassura, Luciano Morselli

"The techniques able to incorporate wastes by means of a heat treatment present the advantage to fix the residue with chemical bonds. Among these techniques there are vitrification and sintering which are characterised by different operating temperatures in the range of 950-1500°C and the involved raw materials develop silicatic crystalline phases and glassy matrices capable to immobilize heavy metal contents in the waste matrix. In this work incinerator bottom ash, polishing and glazing ceramic sludges have undergone to thermal treatments in order to valorise the waste as secondary raw material for the obtainment of re-products. The chemical efficiency of the process adopted has been evaluated by comparing the results of release tests applied to the as-received wastes and to the thermally treated materials in order to verify the effectiveness of the different matrices to fix the waste components.IntroductionVitrification is one of the most promising technological options for the treatment of some kinds of waste. The high temperature involved in the process (1200-1500°C) leads to the complete destruction of organic pollutants, such as dioxins, and glassy network formed can incorporate heavy metals. Some vitrification processes naturally occur: glasses produced by volcanic eruptions, such as obsidians (Na2O-K2O-Al2O3-SiO2) and basaltic (CaO-MgO-Al2O3-SiO2) rocks, are basically inert materials even when they contain toxic elements, because these are embedded in an extremely stable glassy matrix. The disadvantage of vitrification is that it is an energy-intensive process involving relatively high costs, therefore its use is better justified if a high-quality product with optimised properties can be fabricated. The most effective way to improve the properties of the vitrified material is the transformation into glass ceramic. This is a fine-grained polycrystalline material (typically from 50% to 98% of the volume may be crystalline) formed when a glass of suitable composition is heat treated and hence undergone to controlled crystallisation (phenomenon named devitrification). The three key variables in the design of a glass-ceramic are: glass composition which controls glass viscosity related to the effectiveness of nucleation and rapidity of crystallisation; glass-ceramic phase assemblage (that is, the types of crystals and the proportion of crystals to glass) which is responsible for many of the physical and chemical properties; nature of the crystalline microstructure (crystal size and morphology and the textural relationship among the crystals and glass) which is the key to many mechanical and optical properties. In particular, a partly crystalline material can be obtained by powder sintering."

Jan 1, 2008

By Matt Fenwick, Douglas R. Schwarm

Stringent underwater noise limits at the Fairview Ave. N. bridge replacement on Seattle's Lake Union required an innovative approach to supporting the 470-ft long drill trestle. Screw-in foundations would reliably mitigate noise, but the required 500-kip bearing resistance were an order of magnitude higher than typical helical piles. This paper describes the process of designing, installing, monitoring, and testing 22-inch dia. helical piles 80 feet long with 36- and 42-inch dia. helices. A static load test confirmed that the conventional k-factor design method can be extended to capacities of up to 800 kips. A 375 ft-kip drive mechanism had to be fabricated because no North American equipment could supply the necessary installation torque. Real time installation monitoring and later "re-torque" tests confirm that helical piles gain capacity with time, analogous to driven piles under restrike. Underwater and on-land measurements confirmed very low noise, suggesting the possibility of widespread adoption where similar limits are imposed. Overall, this case history illuminates the need for innovative deep foundation types in response to ever-increasing regulatory constraints.

Sep 8, 2021