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By I. Soto, E. Córdova, A. Anani

The new caving megaprojects that are planned to go into production in the next decade have scheduled horizontal developments at very high rates, which are difficult to achieve. Research has been conducted that seeks to model the construction times for underground developments to determine the feasibility of achieving the planned rates. However, these previous attempts do not consider all the operational aspects that make up the mine development cycle. Here, we present a discrete event simulation (DES) model that individualizes each unit operation of the development cycle to determine the construction rates that new projects will be able to attain. The developed model was applied to the New Mine Level (NML) of the El Teniente Division (DET). The results indicate that it would be impractical to achieve the advance rates scheduled in the original plans if the unit operations of the mine continue to be executed using the status quo. The metres developed after six years in the sections analysed can be significantly improved by changing the maintenance strategy for the equipment (457 metres increase), orepass availability (194 metres increase), and the initial planning sequence (1 598 metres increase). It is recommended that the mine implements a flexible maintenance strategy, defines a strategy to ensure and increase orepass availability to contractors, and makes use of current simulation tools for a more robust development sequence planning.

Oct 1, 2022

By S. Dey, C. Bhar, S. K. Mandal

Loading and hauling of ore and waste are the key operations of an opencast coal mine and entail a high operational cost. The productivity of a mine can be increased by reducing the cycle time of loading equipment as well as utilizing dumpers optimally. In this paper we discuss the impact of rock type, bucket fill factor, rock fragmentation, the height of the cut, and angle of swing of the bucket on shovel performance. A time study is conducted on shovels in an opencast coal mine with experimental blasts of rocks to assess the impact of different factors on the performance of the shovel. Based on the data, the authors applied multiple regression (MR) and artificial neural network (ANN) techniques to develop different models for the prediction of the shovel cycle time. Developed models are validated by comparing the predicted data with actual field data. With the help of the best model, the plausible fleet size is determined in order to utilize the shovel and dumper optimally and to improve the performance of shovel–dumper operation.

Oct 1, 2022

By A. J. S. Spearing, M. Sharifzadeh, K. V. Jessu

Empirical pillar design methods are commonly used in the mining industry. The parameters within which these methods are valid are frequently unknown to the user or ignored. In addition, empirical design may not consider essential parameters such as blasting effects, orebody dip and the presence of geological structures, which all adversely affect the stability of the pillars. This can result in potentially serious pillar design strength over-estimates. Although the commonly based tributary area method is generally conservative, as the spans are seldom that large relative to the depth, failing to consider other relevant parameters can result in errors. Problems associated with an under-designed pillar can range from a local pillar collapse to a catastrophic chain reaction collapse (or run). Over-designed pillars are generally safe but reduce the extraction of the orebody, thus adversely affecting the profitability of the mining operation. We used laboratory tests and numerical modelling to understand the effects of pillar orientation, blasting and the presence of discontinuities on pillar strength. Reduction factors were developed with these models to be implemented in conjunction with the existing empirical pillar design methods. For any pillar or mine design, once it is implemented, the actual performance of the system must be checked regularly by observation and monitoring and adjusted if needed. The pillar design approach outlined in this paper can better optimize the pillar mining method by considering other generally ignored but important parameters, thus improving safety, productivity, and economic aspects.

Oct 1, 2022

By Kevin R. Johnson, Matt Caskey, Bryan Plaskett

Working in urban environments presents unique logistical challenges beyond those typically associated with traditional geotechnical design and construction. These challenges can include constrained sites with limited access and laydown area, vibration concerns for adjacent structures, and the need to complete work within limited schedules. When challenging geotechnical conditions like variable bedrock elevations are present, the need to balance performance requirements with logistical constraints become the driving factor when selecting deep foundation systems. This paper focuses on the deep foundations used for a new elevated pedestrian bridge at a major health care facility in Tampa, Florida. In addition to the technical design requirements, the owner required a deep foundation system that could offer low vibrations, rapid production, and clean installation to limit impacts on their properties and the public roadway that separated them. The paper describes the project specific geotechnical and design conditions, describes Ductile Iron Pile design, and focuses on how installation of the system addressed the unique logistical challenges. In addition, the implementation of a full-scale load testing program to assess compression, uplift, and lateral design capacities is presented. This paper represents one of the few published references for Ductile Iron Piles on projects in the United States.

Oct 1, 2022

By Shawna Munn, Carol Dounitch, Erika Acton

The EQ Bank Tower, a 24-storey office tower with 4 levels of underground parking, is currently under construction at 25 Ontario Street in the downtown core of Toronto, Canada. The tower geometry required an 18 m (60 ft) deep excavation inside an existing 3-storey 100-year-old façade, to be retained in place throughout construction. This presented a variety of design challenges that required several innovations and a customized monitoring program. In this paper, we will discuss two major challenges, and highlight the innovative and adaptable solutions carried out using performance-based design leveraging the observational method. The first was installation of a shoring system in a 500 mm (20 in) gap between the historical façade and a live gas main. The second involved excavating 10 m (33 ft) into expansive shale bedrock adjacent to a sensitive neighbouring building.

Oct 1, 2022

By Francisco A. Flores, José L. Aguirre, Héctor A. de la Fuente, Erika Bernal, Jorge Arroyo-Esquedla

This paper presents the analysis, design, and construction of soil improvement for storage tanks foundation support at a site in Tabasco, Mexico. A total of 980 Rammed Aggregate Piers of 12.5 m in length and 0.5 m in diameter were designed and constructed to support four storage tanks. The soil conditions at the site generally consist of loose to medium dense silty/clayey sand to about 8m depth, underlain by very loose to medium dense silty/clayey sand with seams of very soft clay. The use of Rammed Aggregate Piers induced densification of the soil to increase its stiffness and reduce the liquefaction potential to control both static and dynamic induced settlements. Standard Penetration Test (SPT) and Cone Penetration Test (CPTu) explorations were performed prior to and post soil improvement to compare the liquefaction potential and the Factors of Safety associated with the two conditions. Finally, the soil improvement installation rate is presented. Soil improvement using Rammed Aggregate Piers represented a suitable alternative to support storage tanks foundation in potentially liquefiable areas.

Oct 1, 2022

By Soorkty Elarabi

The aim of this paper is to discuss the impact of end bearing plate on the capacity of micropile. Preliminary studies have been made in Sudan in specific area of cohesive soil. Experimental works were carried on a number of micropiles with and without end bearing plate. Same diameters, lengths and techniques of placing cement grout are considered, there after the axial load test applied to find out the capacities of micropiles in both cases. Deduced results in each case show that the end bearing plate has no positive impact on micropile capacity.

Oct 1, 2022

By Vijaya Bhushan Rao, Jason Redgers

The typical Vibrocompaction projects undertaken in the UAE are on reclaimed Sands. These Sands which are predominantly the crushable, calcareous, carbonate sands found locally as opposed to the more common quartz or silica sands that are featured in most design literature. The famous reclamations such as the iconic Palm Jumeirah in Dubai, often have specification for mitigation of liquefaction induced settlements, bearing capacity increases and total and differential settlement requirements. Often these performance targets are achieved by the means of achieving a particular relative density that are generally measured by a defined Cone Penetration Test, CPT targeting values of cone resistance (Qc), MPa at respective depth zones. In this paper some case studies are presented, where soil suitability for deep compaction by vibratory methods was firstly assessed for suitability using the Massarsch, 1991 compactability chart prior to the application of vibrocompaction and its subsequent evaluation. One such project named the Island Development required 17 to 23m depth of penetration only to treat the lower 5 to 6m of sand above rockhead as eventually the top 15m of sand will be further excavated to allow for the construction of basement. The paper will present pre and post CPT results, the results of initial site calibration trials and evaluation of the completed works.

Oct 1, 2022

By Jeremiah M. Jezerski, Russell H. Lutch

The Mount Olivet Road Drop Shaft (MOR-DS) support of excavation (SOE) is a circular unreinforced concrete shaft with an inside diameter of a 30.5 ft (9.3 m) and depth of 120.5 ft (36.7 m), constructed using slurry wall methods. The SOE for the adjacent Mount Olivet Road Approach Channel (MOR-AC) and Mount Olivet Road Ventilation Vault (MOR-VV) near surface structures (NSS) consists of lean mix concrete walls and cement-bentonite walls, respectively, both constructed using slurry wall techniques and reinforced with embedded soldier piles. NSS SOE required multiple levels of preloaded internal bracing, with excavation depths of up to 75 ft (22.9 m). The original design construction sequence for the shaft and NSS SOE required that the MOR-DS be constructed in its entirety and backfilled to ground surface prior to excavation of the adjacent NSS SOE. After installation of the drop shaft and NSS SOE an accelerated construction sequence was implemented requiring the analysis of the excavation support systems to determine if the excavations could be open concurrently without adversely impacting the partially constructed permanent MOR-DS structure. The MOR-DS was analyzed using the finite element analysis (FEA) software, MIDAS GTS, to demonstrate that the unbalanced loads applied to the MOR-DS composite structure due to the revised sequence would not exceed the strength and serviceability requirements per ACI-350 or superseded by the more stringent project requirements. The results of the FEA were used to set limits for geotechnical instrumentation consisting of strain gauges located on the brace levels of the NSS SOE. A comparison of the SOE design hand calculations, FEA model results and instrumentation data is presented.

Oct 1, 2022

By Arash Saeidi Rashk Olia, Dunja Perić

The increasing demand for renewable energy has attracted attention to energy geostructures as means of extracting clean geothermal energy from the ground. To further advance the understanding of soilstructure interaction in energy piles analytical solutions considering the self-weight of the pile were derived. These solutions were then incorporated in recently-derived thermomechanical weightless solutions to provide comprehensive analytical solutions for axial displacement, strain and stress in single energy piles. This was accomplished by comparing responses of energy pile under different loading scenarios that reflect presence and absence of the self-weight. Results of mechanics-based analysis revealed that the self-weight of energy piles embedded in stiff soils has no significant contribution to displacement, strain and stress that develop under thermo-mechanical loads. Overall, the significance of the self-weight contribution depends on the magnitude of thermal load as well as the soil-pile interface stiffness. The stiffness of end restraints imposed to the pile head and tip were also found to play an important role in contribution of self-weight in induced thermomechanical stresses in energy piles.

Oct 1, 2022

By Adrian Gygax, Sarah Gaib, Rod Kostaschuk

The British Columbia Ministry of Transportation and Infrastructure (Ministry) recently completed a slope stabilization project at Ten Mile Slide on Highway 99. The highway is an essential part of the road network connecting the British Columbia (BC) coast with the interior of the province. The landslide was first identified in the mid-1980s and has retrogressed more than 250 m upslope since then, leading to continual and expensive repairs to the highway. The Ministry engaged BGC Engineering Ltd. (BGC) and their structural sub-consultant Gygax Engineering Associates Ltd. (GEA) to develop a stabilization scheme that would halt the slide with an acceptable level of residual risk. The design required careful consideration of construction stages and the stresses induced in the structural components as the slide movement was progressively stopped as construction advanced. Four stabilization design options were shortlisted with the preferred option selected in Fall 2016. The selected solution comprised the construction of five rows of post-tensioned soil anchors upslope of the highway and a tied-back concrete tangent pile retaining wall for the roadway itself as well as reconstruction of the highway alignment, grade and drainage through the slide. Works were installed by top-down construction within defined time allowances stipulated in the contract. Significant engineering was undertaken beyond standard design processes for this complex project, such as comprehensive geotechnical investigations, aerial and terrestrial laser scanning and change detection analyses, pre-production test anchors, detailed geo-structural numerical modelling and due diligence activities to validate and optimize the design. The stabilization works have been very successful with the slide response being as predicted and the highway operating again as full two-lane service.

Oct 1, 2022

By Aaron L. Sacks, David R. Good, Srinivas Yennamanda, Joseph K. Carey

Construction of Parcels 6 and 7, the second phase of The Wharf, began in 2019 and geotechnical construction was completed by December 2020. The overall project consisted of horizontal site, parks, and office buildings. The Wharf’s Phase 2 development includes approximately 1.2 million ft2 (110,000 m2) of above-grade construction including five multi-story, mixed-use buildings constructed over up to three levels of underground parking. The site is located between the WMATA Green Line Tunnels to the north and the Washington Channel to the south; it is bisected by a 108-in. (2740-mm) diameter DC Water outfall pipe. This arrangement, along with very difficult ground conditions, created challenges in the geotechnical design and construction. The support of excavation for this complex project required several different methodologies, including sheet piles, soldier piles, displacement piles, tiebacks, deep foundation anchors, jet grouting, and internal bracing with multi-tier rakers. Ground improvement was also required for support of spread footings in soft soils over the garage footprint. Underpinning of the active 108-in. (2740-mm) diameter DC Water outfall pipe running on a north/south alignment through the center of the site between the two garage structures was also performed. Since portions of the support of excavation are below the groundwater table, an extensive pre-excavation dewatering program was necessary and was separate from the foundation package. On the north side of the project, support of excavation (SOE) was required on a curved alignment, offset approximately 10 ft (3 m) from the outbound Green Line tunnel. Due to the proximity of the tunnel, a stiff, near-zero displacement wall was required. A portion of the buildings extend over the tunnels, imparting load to the tunnels to approximately restore original overburden loads excavated for the basement space. The building foundation is a 3 to 4-ft (0.9 to 1.2-m) thick mat slab anchored into the Potomac clay formation. Continuous movement monitoring of the tunnels was performed by an automated system. This paper describes the design and construction of the SOE and foundations for this high-profile project, which required collaboration between the Owner, Engineer, Construction Manager, and Specialty Geotechnical Contractor to solve many challenges.

Oct 1, 2022

By Douglas R. Hardin, Stanley L. Worst, Joanna Mason

A challenging earth retention project presented itself in Washington, DC in the backyard of the historic House of the Temple (The Scottish Rite of Freemasonry, Supreme Council 33°). Located at 15th St NW and S St NW, a forty-foot-deep underground basement was to be installed adjacent to the existing Temple, a historic Carriage House structure dating back to the 1800’s and across a narrow alley from a four-story brick apartment building. The unique geology of the site included typical urban fill overlying a mixture of loose alluvial soils underlaid by dense marine deposits of the Potomac Formation. The clay, sand and gravel of the Potomac included nested boulders up to three feet in diameter. Design of the earth retention system accounted for ground conditions, installation methods and estimated movement of the system and adjacent structures. Anticipated ground water and unanticipated water from leaky sewers also proved obstacles to overcome during construction. Soldier beams were installed using a variable momentvibratory hammer to minimize disturbance to the historic and sensitive structures. Monitoring of the existing structures included both seismograph and optical targets during installation of soldier beams and as the excavation progressed. Micropiles drilled into the Potomac Formation were a part of the permanent foundation for the new structure. This local case history will delve into the details of the successful design, installation, and performance of an earth retention system and micropiles in a historic and highly congested urban environment.

Oct 1, 2022

By Dominic Ammon, Mark Rothbauer, Paul Landers P. E.

Across the Potomac River from the location of the DFI47 Annual Conference (October 2022), in Alexandria, VA, two large permanent anchored walls with a decorative shotcrete face were recently constructed for the North Hill project, a new multi-family and townhome development. The project was executed with a design-build approach for the Fairfax County Redevelopment and Housing Authority with review by the Fairfax County Geotechnical Review Board. The project was constructed in highly variable Potomac group sediments that include high plasticity clay/silt terrace deposits overlying coarser grained materials. The soils were over consolidated and exhibited potential for slickensides from relief of horizontal stresses from past erosion. The wall system was designed to include deep soldier piles and permanent long strand anchors considering past slope instability in the area. As the construction progressed, problematic soil conditions and water issues required modifications to drilling methods. The two permanent walls spanned 800 and 1,000 feet long with a maximum height reaching 40 feet.

Oct 1, 2022

By David Wilshaw

Continuous Surface Wave (CSW) testing has been the “next big thing” in ground characterization for the last 25 years. The technique uses surface geophones to measure the speed at which Rayleigh waves (generated by a vibratory source) travel through the ground over a range of frequencies. The velocity at which surface waves travel through the ground is directly related to ground stiffness; the velocity of shorter wavelengths is influenced by the stiffness of shallower soil layers, while the velocity of longer wavelengths is influenced by the stiffness of deeper layers. Measuring the surface wave velocity over a range of frequencies, therefore, allows a stiffness / depth profile to be produced. Using the small-strain stiffness data measured by the CSW technique greatly improves the accuracy of simple limit state analyses; the data are also of sufficient quality for use in Finite Element modelling. Nonetheless, the technique has suffered from a perception of high cost, low productivity, and poor repeatability. An improved Advanced Continuous Surface Wave (ACSW) testing system has been developed by Ground Stiffness Surveys in the United Kingdom, has been deployed there commercially for several years, and is now available in the United States. ACSW uses an automated electronic control system that generates vibrations (from a purpose designed and manufactured portable seismic “shaker”) at different frequencies, measured across a 3m (10-foot) array of geophones, linked to a robust data acquisition and analysis software package. The range of applications in geologic and geotechnical site characterization includes rapid preliminary non-intrusive site assessments (utilizing published soil correlations); stiffness profiling to detect discrete layers (such as a variation in rockhead); average stiffness profiling for earthwork or ground improvement control testing, Working Platform stability assessments, foundation settlement analysis, rock quality and rippability assessments, and void detection.

Oct 1, 2022

By Damien Enright, Franz-Werner Gerressen

CFA/ACIP pile is the most used single pass drilling method for deep foundation installations. It is constructed by rotating and driving a Continuous Flight Auger (CFA) into the ground at a controlled speed to the specified pile depth. Concrete is then pumped under continuous positive pressure through the hollow stem of the auger to fill the borehole as the auger is withdrawn. CFA/ACIP piles are preferred due to their high daily production capacity when used in suitable soil conditions. CFA/ACIP piles have been installed in the United States for decades and the industry has seen a huge development in equipment, installation process, monitoring and more. Nowadays, CFA/ACIP piles are installed using fully computer monitored drill rigs rather than a bulky crane and lead setup. Because of the torque and crowd offered by these rigs, piles can be installed to depths of more than 100 feet and diameters up to 48 inches. New age crane-based equipment with leader systems are than welcome to substitute old fashioned bulky cranes These new age crane-based systems combine the benefits of sufficient hydraulic power, fully equipped software, etc. with the additional benefits that they can do single pass drilling without extension systems, even when drill depths of more than 100 feet are required. The paper will explain the construction process and will discuss some jobsite references and experiences made using the new age crane-based equipment.

Oct 1, 2022

By Thai Nguyen Ph. D

Dynamic Load Test (DLT) on driven piles has been performed routinely all over the world. In several recent projects, even 100% testing has become a norm where every single pile is dynamically load tested. In these cases, most piles are of uniform sections, making the field analysis (CASE method) straight forward. The CASE method, which has been used for the last 50 years, however, is only applicable to uniform piles to monitor pile driving stresses as well as pile capacities. Signal matching analysis can handle different configurations. However, the analysis used to require user inputs (i.e., non-automatic). Manual signal matching analysis, which can solve non-uniform solutions, traditionally takes hour(s) to complete for one blow. As such, the real-time pile driving stresses and resistances had traditionally been relying upon the CASE method, using typical range of CASE damping (JC). Until 2021, due to the lack of a rigorous instant signal matching analysis for non-uniform piles, no tool was available to help engineers evaluate non-uniform piles in real-time. An inexperienced field engineer may overlook this shortcoming when evaluating peak driving stresses. Furthermore, ultimate bearing resistances for non-uniform piles may require further evaluation to account for the non-uniformity of piles if relying on the CASE method. This paper highlights recent advances in instant Signal Matching Analysis on non-uniform piles, allowing field engineers to monitor stresses and resistances of non-uniform piles during driving.

Oct 1, 2022

By Andrew Z. Boeckelmann, David S. Graham, Paul J. Axtell

In the last fifteen years, several research studies have evaluated the ability to detect various types of deep foundation concrete integrity flaws with crosshole sonic logging (CSL) and thermal integrity profiling (TIP). This paper synthesizes the findings from the research, focusing on two studies that included CSL and TIP testing of drilled shafts with various types of flaws. The first, a 2016 research study of test shafts for the Wisconsin DOT, included inclusions inside and outside the reinforcing cage, intentional tremie withdrawal during concreting, and soft bottom flaws. The second, a 2021 study of production shafts for the Missouri DOT, included one shaft with and another without soft bottom conditions. After synthesizing the ability of each test method to detect each type of flaw, the paper presents recommendations for improving how CSL and TIP results are evaluated in practice. The recommendations highlight DFI‟s CSL interpretation protocol as well as the importance of evaluating TIP data versus time, not just depth. The paper includes example temperature-versus-time plots for various types of flaws and emphasizes how temperature-versus-time evaluation can be used to distinguish soft bottom conditions from standard bottom-of-shaft temperature roll off.

Oct 1, 2022

By Jeffrey Goodwin P. E., Melih Demirkan Ph. D. P. E., Kevin Tehansky P. E.

Just an hour drive down MD 301 from National Harbor, construction to replace the Governor Harry W. Nice Memorial/Senator Thomas ‘Mac’ Middleton Bridge (HNB) began in spring of 2020. The Maryland Transportation Authority (MDTA) contracted with Skanska-Corman-McLean (SCM) to deliver a new US 301 bridge spanning 1.9 miles from Maryland to Virginia over the Potomac River aiming to improve capacity, safety, and access of the roadway. The project area presented a geotechnical design challenge due to the installation of new bridge foundations in the problematic soils of the Atlantic Coastal Plain alluvial deposits. With the existing bridge remaining in service during construction, and the site’s logistical constraints placing new pile driving operations near existing abutments and piers, a complex instrumentation and monitoring plan was developed to ensure public safety throughout the project. This paper discusses the geological conditions of the project area, the collaborative approach of various design team members to develop an appropriate monitoring plan utilizing various instrumentation, an understanding of baseline conditional movements of the existing bridge, and impact response of adjacent construction activity to help deliver effective new bridge foundations while protecting the old ones.

Oct 1, 2022

By Emre Turk, Suat Gullu, Candan Gokceoglu, Ahmet Sirri, Asli Can

In this study, the ground improvement application applied under the live railway bridge's approach embankments in Sivas, Türkiye was investigated as a case study. The soil profile is mainly composed of orangish conglomerate, clay, silty sandy clay, and under claystone, and mudstone units in the study area. As a soil improvement method, the Deep Soil Mixing (DSM) technique based on the principle of simultaneous mixing the ground while injecting with the water-cement mix, was selected. The application of DSM columns is designed to be 45 degrees horizontal, in order to reach the deepest point of the soft clay units for better improvement against settlement. The core samples were taken from the DSM columns and the compressive strength tests were performed in the laboratory. The results were higher than the minimum designed values. It means that inclined DSM columns were applied successfully, and the excessive settlement problem was solved.

Oct 1, 2022