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By Sam Warren, Antonio Marinucci, Genesis Z. Figueroa, Anne Lemnitzer

Drilled Displacement Piles (DDP) provide an ideal deep foundation solution that combines the benefits of ground improvement with traditional advantages of piling systems. This paper consolidates data from 20 construction projects in which more than 30 DDPs were installed and tested axially. High quality site exploration data (e.g., Cone Penetration Test and Standard Penetration Test) were evaluated to derive geotechnical analysis parameters. The test sites consisted of mostly mixed soil types with strongly stratified layers of sand, silt, and clay. Pile diameters ranged between 40 cm and 61 cm. Test results were compared with predictive methods developed specifically for DDPs as well as methods used in general geotechnical practice. The accuracy of the empirical methods is presented in terms of total pile capacity, pile length/diameter, and soil type. The large majority of all examined methods underpredict the in-situ pile capacities. It was also found that the difference between the tested and predicted capacity is strongly related to the level of improvement in the surrounding soil due to the piles’ installation. A general comparison between predictive axial accuracy and the observed level of ground improvement upon installation is also discussed.

May 1, 2022

By Todd W. Armstrong, Michael D. Reader

"INTRODUCTIONThe Playa Vista Development is the largest urban infill development in the history of the United States. Overall, it encompasses about 1100 acres in the City of Los Angeles and is situated north of Los Angeles International Airport near the Pacific Ocean. The development taking place on the project consists primarily of high-density residential condominiums with 1 to 2 levels of subterranean parking . The geotechnical conditions are typified by high groundwater, soft clays, and liquefaction, in addition to environmental issues such as methane.Due to a combination of the geotechnical factors and noise restrictions, both driven and drilled piles were not feasible once the initial phase of the project was occupied. As a result, the project developer undertook a testing program that consisted of the installation and load testing of 9 piles in order to obtain City of Los Angeles acceptance of a pile installation system that met the site constraints. The testing program was divided between two separate contractors operating on sites set on opposite sides on the street (Figure 1 ). Contractors working in Test Areas A & B employed the ""dry dip"" and ""wet dip"" methods of auger pressure grouted displacement (APGD) pile installation, respectively.This paper summarizes the extraordinary program undertaken to install, document, test, and examine auger pressure grouted displacement piles at this site. The program ultimately resulted in City acceptance of auger pressure grouted displacement piles, a historically difficult challenge given the City's resistance of acceptance of ""new"" technologies.A summary of elements included in the test program are: (1) quality control; (2) load testing; (3) long-term testing; (4) non-destructive testing; and (5) pile exhumation."

Jan 1, 2005

By Mohamed Elgouhary, Carol L. Tasillo, Daniel Koziol

"The Bolivar Dam, located near the Village of Bolivar, Ohio is one of a system of dams designed to provide flood control and water conservation in the Muskingum Watershed. The Bolivar Dam is a “dry dam” that only impounds water during flood events. In order to address problematic seepage, which negatively affects the structural stability of the dam, the U.S. Army Corps of Engineers (USACE) designed a partial-depth and partial-length Seepage Barrier Wall (SBW) through the upstream slope of the dam. For this project, TREVIICOS constructed a 36 in (914 mm) positive SBW by plastic concrete panel wall method and excavated using hydromill and clamshell equipment. The plastic concrete was manufactured on-site, which allowed for enhanced quality control and prompt service. This required the installation, commissioning and operation of a concrete batch plant on-site. This paper presents the challenging aspects of the design, manufacture and placement of the plastic concrete for the SBW in order to meet contract strength and permeability requirements as well as workability requirements necessary for tremie concrete placement.Project General InformationBolivar Dam is located in Northeast Ohio (Fig. 1). It is one of a system of sixteen dam projects designed to provide flood control and water conservation in the Muskingum Basin, which covers 20 percent of the State of Ohio (Fig. 2). Bolivar Dam is on Sandy Creek, a tributary of the Tuscarawas River.The Dam has been constructed, operated and maintained by the USACE, for the Muskingum Watershed Conservancy District. Its construction was completed in 1937 and it has been in operation for flood control since 1939.Bolivar Dam is a rolled earth fill dam, with a typical embankment section made of a central impervious core flanked upstream and downstream by a pervious outer shell with downstream rock toe. The embankment has a maximum height of 87 ft (26.5 m) and a crest length of 6,300 ft (1,920 m), and is comprised of the main embankment starting on the left abutment of about 1,500 ft (457 m) heading to the Northeast, followed by the terrace embankment of 4,800 ft (1,463 m) heading to the North. An upstream impervious blanket extends up to 500 ft (152 m) upstream of the dam along the majority of its length. The outlet works are to the left of the embankment, and consist of an intake structure with six gates, followed by two outlet conduits that finish in a stilling basin. To the left of the outlet works is the uncontrolled emergency spillway, which was doubled in width to 540 ft (165 m) in 1989, and excavated material utilized for construction of a stability berm against the upstream face of the main embankment. A concrete parapet wall was also installed along the upstream side of the crest during this work. In 1982, a toe drain, downstream filter berm and line of 35 relief wells were installed. The filter berm was recently extended an additional 200 ft (61.0 m) downstream and granular filters were placed over an approximate 2000 linear ft (610 m) reach of the lower terrace slope. (Fig. 3)."

Jan 1, 2016

By Allen B. Stanton, Parthiv Brahmbhatt, Michael Grimm, Stanley L. Worst

Constructing a circular shaft consisting of secant piles has its own complications which make it more difficult than typical drilled shaft construction. Add to that performing under low overhead powerlines and sitting inside of a 40-foot deep, 50-foot diameter shaft and it becomes more about logistics than the actual drilling. The complexities associated with the Romeo Arm Interceptor Segment 5 Lining project are the focus of this paper, delving into the details that made it work successfully.

Oct 1, 2022

By Cory McElprang, Enamul Hoque, Aaron Thomas, Scott A. Jacobs

Crosshole Sonic Logging (CSL) only evaluates concrete on the inside of reinforcing cages leaving the outside unevaluated unless other types of testing are performed such as Perimeter Sonic Logging (PSL). While there have been some reports of PSL testing having accurately identified anomalies (e.g. Samtani et al 2005), experience by Case Foundation Company has indicated otherwise where false positives were determined with subsequent coring. Numerous cases of PSL false positives are presented as well as a study where a shaft was installed with both inside and outside tubes, and CSL and PSL data were compared. To date, there is very limited data published on perimeter sonic logging, or Gamma-Gamma Logging (GGL) with tubes on the exterior of drilled shafts. Several cases will be presented where false positives were experienced where PSL testing was performed. In addition, a direct comparison will also be presented where a shaft was installed with both tubes on the inside and outside where CSL and PSL data is compared. BRIEF HISTORY – CSL TESTING AND TUBES ON INSIDE The general procedure of Crosshole Sonic Logging (CSL) testing includes attaching tubes to the reinforcing cage to be able to send a transmitter in one tube and a receiver in another tube with which a sonic pulse is emitted from the transmitter and received in another tube. The time taken for the sonic pulse to travel between the tubes is measured and compared to expected values for the known distance between the tubes. Any increase in time from expected values indicates the sonic pulse traveled through a media other than homogeneous concrete such as objects in the path (spacer wheels, steel bracing, etc.), tube spacing, or soil inclusions. However, variations in arrival time can also result from differences in concrete density. The tubes have traditionally been placed on the interior of the reinforcing cage which protects them during hoisting and placement of the cage and reduces wave refraction caused by modulus of elasticity differences between steel and concrete. This allows the concrete within the interior of the reinforcing cage to be evaluated, but the concrete outside of the cage is excluded from traditional CSL testing. As a result, alternative integrity testing has been developed to not only provide different ways to evaluate the integrity of drilled shafts but to also address the issue of evaluating the concrete outside of the reinforcing cage. These alternative testing methods include Gamma-Gamma Logging (GGL), Thermal Integrity Profiling (TIP testing) and Perimeter Sonic Logging (PSL) which is similar to CSL testing but instead of the tubes placed inside the reinforcing cage, the tubes are placed on the outside of the reinforcing cage as shown in Fig. 1.

Jan 1, 2019

By Aditya Ayithi, William G. Ryan, Dean Herbst

"For rock socketed drilled shafts, it is a common practice not to include the frictional resistance of overburden soils into the nominal capacity estimation. The primary reason often being cited is “overburden soils resistance is negligible compared to that of rock socket resistance.” However, in certain geological conditions, where the rock layer is located at greater depths, friction resistance from overburden layers can be significant. In addition, at such great depths, shaft drilling becomes very complicated and expensive. In these situations, considering the resistance of the overburden layers can be an economic alternative.This paper presents a case study of an Osterberg cell (O-cell) load test conducted on a 161.8 feet long and 78-inch diameter instrumented test shaft. Based on initial designs, a 72-inch diameter rock socket of lengths 23 and 26 feet was required to provide a LRFD factored friction resistance of 3,200 kips. The load test results revealed that the material in the 72-inch diameter socket does not represent a true rock. However, the test results also proved that the factored friction resistance of overburden layers is greater than the required design resistance. Based on the load test results, it was decided to allow the overburden soils frictional resistance to be considered in the shaft design, resulting in significant economic savings.INTRODUCTIONRock socketed drill shaft design guidelines of various State Department of Transportation (DOTs) agencies allow friction and/or end bearing resistance of only the rock socket portion into the design capacity estimation. It is typical to neglect the frictional resistance of overburden soils. However, in certain geological conditions where the rock layer is at greater depths, friction resistance of the overburden soils can be significant. In this case the friction resistance of overburden soils was verified via the specified instrumented O-cell test program and then used as part of the design capacity.PROJECT DESCRIPTIONAs part of I-29 improvement project, Iowa Department of Transportation (Iowa DOT) planned to replace the dual four lane bridges that cross the Floyd River in Sioux City, Iowa with dual six lane bridges (Fig. 1). Expected benefits from this improvement include improved safety, traffic operations and roadway infrastructure conditions.BRIDGE SUBSTRUCTUREThe project consists of two individual bridges; a new south bound bridge and a new north bound bridge. The south bound bridge is 646-ft long and the north bound bridge is 644-ft long. Both are six-span, pretensioned and pre-stressed concrete beam bridges of varying width. Bridge foundations were designed such that the abutments of both bridges will be supported on driven steel piles and the bridge piers will be on drilled shaft foundations."

Jan 1, 2016

By Jon Huff, Jeffrey Donville, Hannah Iezzoni, Dan Stevenson

Occasionally, in the design of deep foundations for a structure, a single deep foundation element may be used to support a building column. The most common type of element used in such cases is a drilled shaft (also referred to as a drilled pier, caisson, or bored pile). However, as installation capabilities have improved, large diameter augercast piles are increasingly more common. While drilled shafts and augercast piles differ significantly in construction methods, in the eyes of the International Building Code (IBC), both are treated as cast-in-place deep foundations and must comply with many of the same code provisions. Deep foundations are required to be braced such that lateral stability is provided in all directions, however isolated, cast-in-place elements that have a diameter (D) of at least 2-feet and a length (L) not more than 12 times the diameter can be an exception. In response to the concerns raised by some member professionals, the Deep Foundations Institute’s (DFI) Augered Cast-in-Place Pile and Drilled Displacement Pile Committee took a closer look at the code and its applications, the historical development of the code language through the years and performed analytical modeling to evaluate the impact of this ratio on a pile’s stability. The question is whether the limiting ratio included in the IBC 2018 code provisions is justified, or whether different criteria should be used to determine when isolated deep foundation members are allowed.

Sep 8, 2021

By Stefan Larsson, Sadek Baker, Razvan Ignat

"This paper describes the execution of two full-scale field tests where a braced steel sheet pile wall interacting with rows of overlapping dry deep mixing columns was first excavated and then loaded to failure. The aim of the tests is to provide insight of the performance of dry deep mixing column rows located in passive zone and interacting with a retaining structure. The column rows were installed perpendicular to the sheet pile walls with two different area ratios, i.e. different distanced between the column rows. Both tests were extensively instrumented with inclinometers, pore pressure transducers, bellow-hoses, earth pressure gauges and strain gauges mounted on the struts. Results of the performedtests will serve as development of design methods for excavation support with columns.INTRODUCTIONDry deep mixing has been used with good results to strengthen the soil when excavations are to be performed in locations with thick soft clay deposits. An application that has increased in recent years is to install columns on the passive side of the retaining structure. Columns can be installed in different patterns but rows, grids or blocks are the most common arrangement. The use of column type ground improvement installed on the passive side of a retaining structure has been documented for a few field cases, Tanaka (1993), O’Rourke et al. (1997b), O’Rourke and McGinn (2006), Ou et al. (2008). By improving the soil on the passive zone, the passive earth pressure in front of the retaining structure is increased. This has proven to reduce the excavation induced deflections behind the retaining structure, reduce the structural forces (bending moment in the retaining structure, strut and anchor forces) and improve the safety against basal heave failure. The main focus of the conducted measurements within these cases has been on recording deflections and structural forces on the retaining structure and there is very little documentation available of the stress-strain behavior of the improved soil acting on the passive side of the retaining structure.Two full-scale tests of braced steel sheet pile walls interacting with rows of overlapping dry deep mixing columns were first excavated and then loaded to failure was conducted during the spring-summer of 2014. This paper briefly describes the test set up, instrumentation, test procedure and some selected results from one of the conducted tests."

Jan 1, 2015

By C. Vipulanandan

Installation procedure and the quality of the material used in the construction have significant effects on the behavior of the Auger Cast in Place (ACIP) piles. In this study, Installation and curing of a 760 mm (30 in.) diameter and 12 m (39 ft) long ACIP pile with a design capacity of 1140 kN (128 tons) in hard clay was investigated. Construction quality was monitored using the automated monitoring system where the volume of grout pumped and the pressures were monitored with depth. The curing of the pile was monitored using axial vibrating wire strain gages at four levels and lateral vibrating wire strain gages at two levels. The residual strain and temperature profile in the curing pile was monitored over a period of week to determine the appropriate time for load testing the pile. Axial behavior of Auger Cast in Place (ACIP) Piles in hard clay was studied using full scale load test on an instrumented pile. The load-settlement and load transfer relationships of the pile was investigated based on the load test results. Development of skin friction in the load test pile and the reaction pile was also investigated.

By Haoran Zhang, Chu Ho

A recent design-build project in New York involved various degrees of additions and improvements to four existing transit stations. Reuse of the existing foundations was considered a more sustainable alternative than constructing new foundations for the project. This approach mitigated the extent of demolition work and limited the amount of downtime for track operations. A key challenge for reusing the existing foundations was the lack of as-built drawings. In order to obtain some measure of confidence for the proposed foundation reuse, non-destructive investigation technology was adopted to evaluate the structural integrity of the piers and foundations. A total of 47 piers for the existing passenger platform were investigated for possible reuse. Several test pits, excavated to verify the foundation type and configuration, indicated the piers were founded on a combination of shallow footings and drilled shafts. Pile integrity tests were performed to verify the length of the drilled shafts. Geotechnical capacity of drilled shafts was evaluated for side friction and end bearing resistance, and confirmed using a proof load test conducted from the existing platform structure. This paper presents the investigation methodology and discusses the approach adopted for geotechnical design of the existing foundations for reuse.

Sep 8, 2021

By Greg Plutko

Laboratory testing has shown that the Marsh Funnel test can be significantly impacted by long-chain polymer entanglement. In general, shorter hydration time leads to more chain entanglement which in-turn, leads to higher marsh funnel values that values seen for longer mixing. This trend makes it very difficult to predict funnel-viscosity on successive days. Data is presented which helps to explain this chain interaction effect on Marsh Funnel data and how it differs from traditional Fann viscosity. The data suggest that this long-chain polymer entanglement occurs more in samples with less hydration time and decreases as hydration time increases. There is also suggestion that higher polymer concentrations have a greater drop-off in marsh funnel viscosity for a given aging length than do lower solids slurries. Fann rheology was shown to be much less impacted by the hydration time of the PHPA polymers than was Marsh Funnel viscosity. This suggests that the Marsh Funnel viscosity is impacted by some aspect of the slurry that does not affect Fann rheology as strongly. It is known from literature that longer-chained polymers have more potential to entangle and our data support the theory that the Marsh funnel viscosity is greatly impacted by this polymer-chain ‘roping’ entanglement.

By Sylvia S. Eskander, Sherif S. AbdelSalam, Mona B. Anwar

Expanded Polystyrene (EPS) geofoam has long been used in numerous geotechnical applications due to its lightweight and durability. Among these applications is the use of EPS as an alternative fill material to conventional roadway soil embankments. This study investigates the benefits of using EPS roadway embankments to reduce the induced stresses and strains on the underlying peat and soft clay. Firstly, mechanical and interface properties of the EPS were acquired from a companion study that also considered the cyclic loading and creep effects. In order to determine the actual stress-strain distribution within the EPS blocks, a physical prototype was developed in this study with overall dimensions of 1.2 x 1.0 x 0.5 m, with a density of 35 kg/m3. The prototype EPS blocks were subjected to cyclic loading with intensities ranging from 10 to 50 kN. Then, a numerical model was developed to simulate the behavior of EPS roadway embankments. The numerical model outcomes were verified against the prototype measurements. A parametric design study was also conducted to develop a correlation between EPS embankment height and the stress-strain that occur in the underlying strata. Results showed that EPS embankments could reduce stress and settlement in the underlying soil by about 40% and 54%, respectively. EPS APPLICATIONS AND BACKGROUND Expanded Polystyrene (EPS) geofoam blocks have been effectively used during the past several decades in numerous geotechnical applications. EPS static and dynamic properties as well as interface behavior were extensively characterized in various published studies such as that conducted by Horvath, 1994; Stark et al., 2004; Zarnani and Bathurst, 2008; Trandafir et al., 2010; Athanasopoulos et al., 2012; AbdelSalam and Azzam, 2016; and others. However, to be able to use locally produced EPS blocks, its physical and mechanical properties must be thoroughly determined. The lightweight and compressible material of EPS geofoam makes it suitable both as a backfill and for absorbing pressure in both the vertical and horizontal directions. Kim et al. (2010) adopted EPS as an alternative for soil backfill around buried pipes; their model showed a reduction in the vertical stress acting on the pipes by up to 36%. Oshati et al. (2012) presented a case study of a field-instrumented box culvert with EPS blocks on top, which reduced vertical stress by 58%. Meguid et al. (2017) used an EPS inclusion to surround culverts and achieved up to 72% stress reduction, depending on the EPS density and the culvert depth to width ratio. AbdelSalam et al. (2017) used a relatively thin EPS inclusion behind flexible cantilever retaining walls, verifying that the lateral pressure can be significantly reduced by 25%; they also developed a design chart for this application. Moreover, AbdelSalam et al. (2019) investigated the use of EPS as a lightweight alternative for soil backfill above shallow tunnels. It was found that EPS had created a differential movement between the wedge located above the tunnel and the neighboring soils, which accordingly reduced the vertical stress acting on the tunnel by 85%, due to the use of lightweight EPS material and positive soil arching.

Jan 1, 2019

By Lisa R. Papandrea, David Chen, Walter E. Kaeck

"Construction of the University at Buffalo’s new School of Medicine and Biomedical Sciences (UB-SMBS) required excavation in variable ground to a depth of more than 40 ft adjacent to the NFTA Metro subway and Allen Street Station. Complicating the building design and construction, the new medical facility incorporates the at grade Station entrance building, requiring a combination of temporary and permanent excavation support structures, a complex sequence of ground support installation, and a mix of shallow and deep foundations to accommodate the large floor spans and concentrated column loads introduced by building over and adjacent to the Station entrance. Excavation and foundation construction was challenged by a stratified soil profile with interlayered and sensitive sands, silts and clays and complicated groundwater regime with perched and regional water tables. Efficient construction required ongoing coordination between the design team and contractor, careful field observation, and construction monitoring in several facets of below grade construction. This paper describes the design and construction of excavation support structures and foundations to manage the variable ground, congested site conditions, and complications of building adjacent and above an active subway station. Use of site instrumentation and monitoring data to provide guidance in construction when unanticipated field conditions arise is illustrated. Lessons learned in installation and sequencing of excavation support, groundwater control and foundation construction are also discussed.INTRODUCTIONUniversity at Buffalo President Satish K. Tripathi heralded the new School of Medicine and Biomedical Sciences (UB-SMBS) as a future linchpin of UB’s downtown campus that will revitalize the area and enhance western New York’s emerging bio-sciences corridor. The $375 Million, 628,000 square foot, eight story building with two basements is expected to house 2,000 faculty, student and staff allowing UB to increase class size from 140 to 180 students. It will be constructed above the Niagara Frontier Transportation Authority’s (NFTA) Allen Street Station, creating a direct connection to Buffalo’s light rail system. The 200 ft x 400 ft site is bounded by Main Street, High Street, Washington Street and the Roosevelt Apartments and adjoining parking lot at the west, north, east and south respectively, as shown in Figure 2. Groundbreaking for the new building was in October 2013 with the facility scheduled to open in early 2017."

Jan 1, 2016

By WenJun Dong

This paper presents the stability assessment of the steel pipe piles that are used to support a deadman beam to anchor an adjacent bulkhead wall. Finite element analyses are performed to assess the stability of the bulkhead wall and determine the required tie-back force to the pile. The piles are relatively close to the bulkhead wall such that their soil resistance wedge zones are not fully developed but truncated by the bulkhead wall. The reduced lateral resistance capacity of the anchor piles is determined by applying the Coulomb wedge method on the truncated soil passive zones between the pile and wall. Both the conventional soldier pile stability (in terms of force and moment equilibrium) and Winkler soil spring (for soil-pile-interaction) analyses are used to assess the stability of the anchor piles.

Sep 8, 2021

By Richard D. Luark, Fernanda S. Madrona

Designing temporary retaining systems that allow for deeper excavation amid the existing urban infrastructure has become a challenge. A 60-foot-deep excavation in downtown Seattle was required to construct five levels of below grade parking for a 35-story high-rise building, Tower 12, next to an existing 20-story tower with three levels of below grade parking, separated from the project by an 18-foot wide alley. The solution was to combine two temporary excavation support systems, soil nailing and anchored soldier piles, to work within the site constraints. Densely-arranged, short-length soil nails were used to support the upper 30 feet of the excavation, while the lower 30 feet of the excavation was supported with soldier piles combined with steeply-inclined, high-capacity ground anchors, which extended below the adjacent building foundations. The combined temporary support system eliminated the need for internal bracing, reducing construction cost and schedule. The performance of the combined soil nail and soldier pile system was monitored with an inclinometer and optical survey monitoring, which demonstrated the performance of the combined temporary support system. This paper provides a discussion of the advantages of combining different excavation systems and an analysis of movement monitoring data collected. SITE CONDITIONS AND PROJECT INFORMATION Tower 12 consists of a 0.45-acre development with 36-stories of mixed, residential and commercial use with four levels of below grade parking. The project site is bounded by the Cristalla Condominium to the north, Virginia street to the south, 2nd Avenue to the East, and an 18-foot wide private alley to the west. The One Pacific Tower Condominium, which has three levels of below grade parking, was located to the west across the alley. A site layout plan is presented as Figure 1. As shown in Figure 1, the construction of the west wall required a maximum 51-foot-deep excavation, from elevation (EL) 162 feet to EL 111 feet. Adjacent to the west wall, the existing alley grade varies from elevation 154 to 161 feet, leaving a narrow block of soil 18 feet wide and up to 42 feet high to be shored along the alley in order to reach the One Pacific Tower bottom of mat foundation at EL of about 120 feet. In addition to the existing One Pacific Tower Basement wall, site constraints included existing utilities along the alley such as an existing 4.5-feet wide by 7-feet high vault, with bottom at approximate EL 146 located 10 feet from the back face of the proposed Tower 12 basement wall.

Jan 1, 2019

By Chetan D. Savani, Mike K. Muchard

The necessity to evaluate undocumented foundation lengths is essential in assessing the useable life, need for scour protection, retrofitting, or full reuse of existing bridge foundations. For this purpose, Parallel Seismic Testing (PST) has the best accuracy and is applicable to the widest range of foundation configurations used in bridge construction of any test method. Although not limited to bridges, PST case studies are presented involving two bridges. To preface the case study discussions, an overview of the PST method is given along with its results and analysis thereof. In one of the cases, we were afforded the rare opportunity to see the existing piles being extracted long after the PST testing program was completed. The resulting Class A prediction reaffirms the accuracy of the method. Versatility of the PST method is also exemplified in the two cases presented, where unique situations from complex foundation systems were overcome by analysis to provide successful results.

By Tim Chapman

This general report considers what promoters of deep basement projects want from their teams and whether they get it often enough. Most large projects are based on complex financial models where the funding is related to a future income stream. Project delays and cost over-runs can critically affect the financial model. Too often, delays and cost over-runs originate in the substructure and foundations. We must take positive steps to improve our industry's reputation for reliability.

Jan 1, 2006

By Paul A. O’Brien, Gary A. Chapman, Thomas G. Cuniowski

"The new Amcor B9 paper mill in Botany, NSW, Australia, involved the design and construction of a new paper mill founded within the Botany Basin Sediments. There were numerous design and construction challenges to address, including tight settlement tolerances for the paper machine footings (6 mm total and 1/2000 mm differential limits), high variable and cyclic loads, deep (>25 m) bedrock and uncontrolled fill material across the site. The mill structure design incorporated a deep driven precast and CFA piled foundation solution, with a comprehensive swathe of testing to validate pile capacity and expected settlements. The pile design for the mill structure included the installation of approximately 1000 piles, with pile testing comprising dynamic testing and a static load test on precast piles. With consideration of Sydney’s increasing demand for development space in relative close proximity to the city’s CBD, industrial areas in the Botany Bay area are likely to make way for heavy or complex commercial and residential structures. Therefore, a better understanding of the engineering behaviour of sediments underlying these areas would allow for efficient foundation solutions. This paper presents a discussion on effective foundation testing techniques and the effects that the behaviour and characteristics of the Botany Bay sediments impose on deep piled solutions.2 PROJECT DETAILS2.1 New paper millThe project involved the construction of the largest recycled paper machine in Australia. The paper machine is 330 m (1080 ft) long, 22 m (72 ft) high, and capable of producing 1.6 km (1 mile) of paper per minute. Construction commenced in early 2011 and new paper mill officially opened in early 2013. The early works contract was awarded to Baulderstone Construction Pty. Ltd. (Lend Lease Corp. Ltd.), with the D&C contract awarded to a consortium headed by Leighton Contractors Pty. Ltd. (CPB Contractors Pty. Ltd.), which included Golder Associates Pty. Ltd. as the geotechnical designer and reviewer.2.2 Site history and effect on local topographyThe site has been used as a paper mill since 1902, and as such, has layers of uncontrolled fill and buried objects within the upper fill materials associated with historical industrial use. The fill material generally comprised of loose and very loose sands, with isolated pockets of cohesive materials, peats, pulped paper and general construction waste. In addition, during construction, underground storage tanks were identified at depth, indicating the historical extent of filling across the site was extensive. The presence of this generally uncontrolled fill was a factor for determining that the most cost effective foundation solution for the paper mill was piled foundations, to bypass these materials."

Jan 1, 1900

By Eric P. Bregman

As part of an on-going effort to improve water quality and reduce discharge into Boston Harbor, the Massachusetts Water Resources Authority (MWRA) East Boston Branch Sewer Relief Project was designed under a Federal mandate from the United States Environmental Protection Agency (EPA) to upgrade the aging sewer system, increase system storage and greatly reduce the volume of combined sewer overflows into the Harbor. The project scope of work includes the installation of over 2 miles (11,800 linear feet) of 36-inch and 66-inch diameter sewer relief piping, twenty (20) temporary shafts and an approximate 100 foot open cut section, located within the densely populated neighborhood of East Boston, Massachusetts. This area is a former marshland backfilled in the early to mid 1800?s where busy commercial streets co-mingle with thickly settled residential houses. The subsurface conditions present within Boston?s complex geology include the presence of subsurface contamination as well as complex networks of underground utilities. Additional site limitations included low headroom, noise, and traffic restrictions. Together these limitations required the design of individual earth support systems, tailored for each shaft location. Moreover, challenging subsurface conditions identified during construction required design modifications to minimize cost and schedule impacts related to construction dewatering, treatment of contaminated groundwater, internal bracing, and utility relocations. This paper provides a case history of the Geo-structural design and performance of various earth support techniques utilized to construct jacking and receiving shafts designed to launch and receive two (2) micro-tunnel boring machines (MTBM) and to support the construction of new deep shaft structures in an urban coastal area.

By Eric P. Bregman, Franklin M. Grynkewicz, John E. Regan

"As part of an on-going effort to improve water quality and reduce discharge into Boston Harbor, the Massachusetts Water Resources Authority (MWRA) East Boston Branch Sewer Relief Project was designed under a Federal mandate from the United States Environmental Protection Agency (EPA) to upgrade the aging sewer system, increase system storage and greatly reduce the volume of combined sewer overflows into the Harbor. The project scope of work includes the installation of over 2 miles (11,800 linear feet) of 36-inch and 66-inch diameter sewer relief piping, twenty (20) temporary shafts and an approximate 100 foot open cut section, located within the densely populated neighborhood of East Boston, Massachusetts. This area is a former marshland backfilled in the early to mid 1800’s where busy commercial streets co-mingle with thickly settled residential houses.The subsurface conditions present within Boston’s complex geology include the presence of subsurface contamination as well as complex networks of underground utilities. Additional site limitations included low headroom, noise, and traffic restrictions. Together these limitations required the design of individual earth support systems, tailored for each shaft location. Moreover, challenging subsurface conditions identified during construction required design modifications to minimize cost and schedule impacts related to construction dewatering, treatment of contaminated groundwater, internal bracing, and utility relocations.This paper provides a case history of the Geo-structural design and performance of various earth support techniques utilized to construct jacking and receiving shafts designed to launch and receive two (2) micro-tunnel boring machines (MTBM) and to support the construction of new deep shaft structures in an urban coastal area."

Jan 1, 2017