Bored Pile Construction Challenges in Highly Variable Limestone for a Supertall Building

"This paper presents a case study on bored pile construction in challenging karst conditions below a supertall building in Kuala Lumpur. Innovative design and construction techniques helped keep the project moving through very difficult and unpredictable geological and drilling conditions. The development encompasses about 12,400 square meters and includes a 77-story tower, a 59-story tower, a five-story podium, and four contiguous basement levels. The site is underlain by a residual soil derived from a siltstone/claystone (the Kenny Hill formation), then limestone bedrock. Subsurface conditions are relatively uniform within the Kenny Hill and highly variable at the limestone surface. Extreme cases included 40-meter-tall underground caverns, 40-meter-tall pinnacles, and a 50-meter-tall underground rock ledge. Local piling practice in Kuala Lumpur involves deriving pile capacity entirely in the Kenny Hill formation to avoid the unpredictable limestone surface. However, the massive tower foundation loads and relatively shallow bedrock required the piles to be socketed in the limestone. The 77-story tower will be supported by 2.0- and 2.2-meter-diameter bored piles 50 to 100+ meters long, socketed in limestone, with working loads between 40 and 70 Meganewtons. Two Osterberg-cell load tests were used to develop a site-specific rock socket skin friction correlation with RQD. Exploratory rock probes were drilled at each pile location to design the rock socket length based on the rock quality and sloping rock conditions. The rock mass was pressure-grouted during each rock probe to improve the rock quality and fill voids in the rock.INTRODUCTIONThe Kuala Lumpur City Centre, home of the Petronas Towers and the world’s deepest foundations, will be the future home of a new supertall tower. The 77-story tower will be supported by a piled-raft foundation that relies on piles terminating in the highly erratic, karstic Kuala Lumpur limestone formation. The high building loads coupled with relatively shallow limestone across the majority of the tower footprint forced the piles to extend into the limestone."