Piling Industry Canada

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Issue 1 | 2012 Cover photo courtesy of

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Piling Industry Canada

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Our support systems extend far below the surface The only company that offers you all four types of support systems:

> Concrete Pile

> Steel Pipe

> H Pile

> Sheet Pile

We carry ASTM A252, A139, A53 B AWWA C200, API & CSA Specifications

Supporting the construction industry since 1953 Calgary

Delta

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USA

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#6-8500 River Road

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Phone: 403.236.1788

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For more than 90 years, Equipment Corporation of America has been a premier distributor of Foundation Construction Equipment. Our success and longevity is a direct result of the relationships we’ve built by using high quality equipment and best-in-class service.

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Table of Contents Canada

Published by

DEL

Communications Inc.

Piling Industry News........................................................................................................6 The Latest from Intermat

WHAT’S TRENDING, NEW EQUIPMENT AND NEWS FROM THE THREE SHOWS...................... 6

Don’t Get Stressed

LET THE USER BEWARE OF THE BETA METHOD............................................................................... 18

Upgrading Gear

WESTCO DRILLING & PILES LTD. INVESTS IN A SECOND RIG...................................................... 20

Control of Contaminated Groundwater USING SEALABLE JOINT STEEL SHEET PILING, CONTAMINANTS

ARE PREVENTED FROM MOVING OFF SITE........................................................................................ 22

Combining Forces

TADANO MANTIS PARTNERS WITH BERMINGHAM FOUNDATION SOLUTIONS.................. 26

Offering More IRVING EQUIPMENT PROVIDES ATLANTIC CANADA

Suite 300, 6 Roslyn Road Winnipeg, Manitoba Canada R3L 0G5 President: David Langstaff Publisher: Jason Stefanik Managing Editor: Carly Peters carlypeters@mts.net Sales Manager: Dayna Oulion dayna@delcommunications.com Advertising Account Executives: Jennifer Hebert | Michelle Raike Production services provided by: S.G. Bennett Marketing Services www.sgbennett.com Art Director: Kathy Cable

AND BEYOND WITH SERVICE AND SKILLS.......................................................................................... 28

Layout & Design: Dana Jensen

Cross Over

Advertising Art: Julie Weaver

FLATIRON USES POSEIDON 2-7’ BARGES ON THE LAKE CHAMPLAIN PROJECT................... 30

Test Design

RIVER WORK ON NEW YORK’S TAPPAN ZEE BRIDGE NOW UNDERWAY................................. 32

Flying Right

X52 KIRKWOOD TO TRIENDA 138KV ISLAND SPAN FIX................................................................. 34

Mind the Gap

THREADING PILES THROUGH LONDON’S CONGESTED UNDERGROUND............................. 36

Big Links

WORLD’S LARGEST PILING LINKS HONG KONG, MACAU AND ZHUHAI................................. 40

All Around the World

A PROFILE ON TWO OF LIEBHERR’S INTERNATIONAL PROJECTS.............................................. 44

www.pilingindustrycanada.com

© Copyright 2012, DEL Communications Inc. All rights reserved.The contents of this pub­lica­tion may not be reproduced by any means, in whole or in part, without prior written consent of the publisher.

While every effort has been made to ensure the accuracy of the information contained herein and the reliability of the source, the publisher­in no way guarantees nor warrants the information and is not responsible for errors, omissions or statements made by advertisers. Opinions and recommendations made by contributors or advertisers are not necessarily those of the publisher, its directors, officers or employees.

Publications mail agreement #40934510 Return undeliverable Canadian addresses to: DEL Communications Inc. Suite 300, 6 Roslyn Road Winnipeg, Manitoba Canada R3L 0G5 Email: david@delcommunications.com Printed in Canada 06/2012

Cover photo courtesy of

Liebherr HS 885 HD duty cycle crawler crane in pile driving application for the construction of a complex of buildings for the Eurovision Song Contest 2012 in Baku, Azerbaijan. An arena was specially built for the Eurovision Song Contest which already took place in the Azerbaijan capital Baku in May 2012. For this project Azenco chose two Liebherr duty cycle crawler cranes, type HS 885 HD, with fixed leader LRH 400. The two Liebherr duty cycle crawler cranes drove the concrete piles into the ground using hydraulic hammers and thus prepared the ground for the construction of the new arena called Baku Crystal Hall. Thereby the hydraulic hammers were driven by the on-board hydraulics of the duty cycle crawler cranes.

4 PIC Magazine • June 2012

CanadaIndustry News Piling Piling Industry Canada Magazine is now online Love Piling Industry Canada Magazine, but hate waiting for your copy?

Now you can read the magazine online at www.pilingindustrycanada.com, as well as keep up-to-date on industry news, and events.

The new website also features a option to fill out a free company directory listing, which will be included in Piling Industry Canada Magazine’s Fall/Winter 2012 edition.

New accessories for augered cast-in-place / CFA pile installation monitoring Pile Dynamics, Inc. has released new accessories and software for its Pile Installation Recorder (PIR). Debuting are the PIR Viewer and a new version of the PIRPLOT data processing and reporting software.

The Pile Installation Recorder is an Automated Monitoring Equipment that records and displays grout volume versus depth, along with other parameters that help the construction of augered cast-in-place (ACIP) and continuous flight auger (CFA) piles. Even before its new enhancements, the PIR had won awards (Ohio New Product Award in 2000) and praise: “Even though I have been installing auger cast piles for almost 20 years, there comes a time where I have to work in a region of the country which requires me to use local union help. My last project was in Syracuse, NY. We had to install 200 CFA piles 16 inch diameter up to 80 feet deep. When you are working in NY, you need to use NY licensed operators. Qualified operators they were, but they lacked the technical knowledge needed to successfully drill and pull a CFA pile properly. Who steps in? Pile Dynamics with their PIR. With the new

colour screen and simple user friendly controls, my green operator was pumping piles out like a seasoned operator, making my job easier and more productive,” states Jason Matthew Crisp, project superintendent, HJ Foundation, Miami, FL, December 2011.

The PIR Viewer will make Matthew even more productive. It is a handheld WI-FI device that allows a supervisor or inspector to see, in real time, the information that the PIR is displaying to the operator in the

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6 3911-Spiralco-Publicité PIC Magazine • June 2012revue_REV6.indd

1

11-11-04 16:10

Your True Project Partner

© 2011 Skyline Steel, LLC. Skyline Steel is a wholly owned subsidiary of ArcelorMittal, the largest and most globally integrated steel company. (07-11)

Skyline (PHP) Canada Ltd / Ltée, is a wholly-owned subsidiary of Skyline Steel, a premier steel foundation supplier serving the US, Canada, Mexico, Central America, Caribbean and South American markets. Skyline Steel has over thirty sales offices across two continents and a robust infrastructure comprised of manufacturing, coating, and fabrication facilities; dozens of stocking locations; an efficiently-coordinated supply chain; and exclusive engineering support. Collectively, these functions support a dynamic sales team that supplies hundreds of thousands of tons of steel foundation products to the industry every year.

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• Widest Range of Hot Rolled and Cold Formed Steel Sheet Pile Available in the Industry

• Accepted by DOTs in Seismically Active Areas

• Complementary accessories designed to develop the full capacity of bars

• Spiralweld Pipe is Structurally Equal to API Pipe*

• Micropile casing accessories in stock for immediate delivery

*According to full-scale university study conducted in 2009

• Multiple tooling items for Micropile casing installation

• Z-piles, Flat Sheets, Combination Walls

Skyline’s flagship products include H-piles, pipe piles, hot rolled and cold formed steel sheet piles, threaded bar, micropiles, accessories, structural shapes and connectors. Of the products we manufacture and supply, 80% are made from recycled steel and are 100% recyclable.

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Innovative Applications and Engineering Expertise

CanadaIndustry News Piling crane cab. This enables the supervisor to stop the crane operator sooner in case there is a concern. In the past, the pile had to be completed and summary report generated before an inspector could review the installation details. The user of the PIR Viewer pushes of a button to flag when grout return occurs, and a may use a logging feature to manually count grout pump strokes. Once the pile is completed this information may be compared to the PIR summary report. Post processing with PIRPLOT generates customizable presentation quality tables and graphs.

In addition to the PIR, Pile Dynamics produces several other quality assurance and quality control products for the deep foundations industry. Its products are recognized throughout the world as the ultimate solutions for testing and monitoring of deep foundations. The company is based in Cleveland, OH and has commercial representatives worldwide.

For more information visit www.pile.com.

Allnorth Acquires XXL Engineering Ltd. of Calgary, Alberta Allnorth Consultants Limited is pleased to announce that effective February 21, 2012 we have acquired XXL Engineering Ltd of Calgary, Alberta. XXL was founded in 2000 and since that time has provided extensive services to the Oil & Gas Industry in western Canada. XXL brings in excess of 30 highly motivated and experienced professionals to the Allnorth team.

Collectively we will provide new and challenging opportunities for our combined team, and will be able to offer a wider range of services to our mutual client base. We look forward to integrating the two teams into a single cohesive unit.

The range of professional services includes: Mechanical/Structural/ Civil/Process/EI&C Engineering; Environmental Permitting and Planning; Project and Construction Management; Constructability and Optimization Reporting; 3D Scanning, Legal & Construction Surveying; Materials Testing & QA/QC Services.

Bruce MacTavish PEng will lead our Calgary team as Division Manager working with the Allnorth Leadership Team to ensure that our combined reputation for quality and cost effective engineering solutions continues. Our Calgary office is located at: Allnorth Consultants Limited #101, 807 Manning Road NE Calgary, Alberta T2E 7M8 Phone: 403-717-2370.

Allnorth has been providing consulting services since 1978 to clients in the Mining, Oil & Gas, Pulp & Paper, and Infrastructure sectors in Canada and globally.

Our client relationships have been built on trust, quality service, timely response to issues, commitment to availability, flexibility in scheduling, and providing logical solutions that are practical and economical to construct. We have proven experience and are well known for our professional accreditation, expertise, skills, experience, on-time record, and commitment to quality, safety, and the environment.

If you have any questions please call Bruce MacTavish at 403-717-2370 or Darryl Bell at 250-299-9979.

AECOM again named one of the “World’s Most Ethical Companies” AECOM Technology Corporation, a leading provider of professional technical and management support services for public and private sector clients in more than 130 countries around the world, has been named one of the World’s Most Ethical Companies for 2012 by the Ethisphere Institute.

The designation recognizes firms based on their commitment to ethical leadership, compliance practices and corporate social responsibility.

This is the second year in a row that Ethisphere has named AECOM as one of the World’s Most Ethical Companies.

“We are honoured to be named one of the World’s Most Ethical Companies for the second-straight year,” says John M. Dionisio, AECOM chairman and chief executive officer. “AECOM is committed to conducting business in an ethical manner – with our dedication to integrity driving our daily activities around the world. Guided by our Core Values, we are committed to delivering innovative, sustainable solutions to address environmental challenges; keeping our people, clients and partners safe in all of our activities; contributing time and funds to support important causes throughout our communities; and, above all, serving our clients with the highest ethical standards.”

For more information about the 2012 World’s Most Ethical Companies methodology and list, visit http://www.ethisphere.com/wme/.

About AECOM AECOM is a global provider of professional technical and management support services to a broad range of markets, including transportation, facilities, environmental, energy, water and government. With approximately 45,000 employees around the world, AECOM is a leader in all of the key markets that it serves. AECOM provides a blend of global reach, local knowledge, innovation, and technical excellence in delivering solutions that create, enhance and sustain the world’s built, natural

8 PIC Magazine • December 2011

CanadaIndustry News Piling and social environments. A Fortune 500 company, AECOM serves clients in more than 130 countries and had revenue of $8.1 billion during the 12 months ended Dec. 31, 2011. More information on AECOM and its services can be found at www.aecom.com.

Japan’s newest skyscraper uses special technology intended to protect against quakes A Tokyo developer took visitors up the world’s tallest freestanding broadcast structure in April, a 634-meter (2,080-foot) tower with special technology meant to withstand earthquakes that often strike Japan.

The Tokyo Skytree is the world’s second-tallest structure behind the 828-meter (2,717-foot) Burj Khalifa in Dubai, according to owner Tobu Tower Skytree Co. The needle-like radio and television tower opens to the public in May. Journalists given a tour earlier in the month saw sweeping if hazy views of the Tokyo skyline. It took about 50 seconds in a high-speed elevator Tuesday to zip up to the lower observation deck at 350 metres (1,148 feet), and another 30 seconds to reach the higher deck at 450 metres (1,476 feet).

The Skytree has a restaurant and two cafes on the observation decks, a vertigo-inducing glass floor that allows visitors to look straight down, and an emergency staircase with 2,523 steps.

The tower was constructed with extremely strong steel tubes surrounding a central concrete column that are structurally separate from each other in the tower’s mid-section. In the event of an earthquake, the concrete core and steel frame are designed to offset each other to reduce the building’s overall motion.

The Skytree has been built to stand firm even if a magnitude 7 quake were to strike beneath the building, said Sho Toyoshima, a spokesman for Tobu Tower. He said the tower sustained no structural damage from the magnitude 9.0 quake that struck off Japan’s northeastern coast last March, even as it was being built.

The Skytree is expected to bolster television and radio transmissions in the capital region. Owners hope it will also become a new tourist destination in Tokyo.

New accessory for Cross Hole Sonic Logging makes testing more comfortable Cross Hole Sonic Logging (CSL) is one of the most popular testing methods to evaluate integrity of drilled shafts. It involves inserting probes – two at a time – in tubes built into the shafts especially for the test. The probes, on spooled cables, are lowered to the bottom of the shafts and pulled back up. As they travel along the shaft, one of the probes emits a sonic wave, and the receiver probe picks it up after it travels through the concrete. The intensity and time of arrival of the wave at the receiver probe is indicative of concrete quality. The test is typically performed in shafts with at least four access tubes, but sometimes as many as 10. Test procedures require filling the tubes with water, and testing all possible paths between tubes. Remember your combinatorial analysis and you’ll figure out that those probes will be pulled many times (15 for a shaft with six tubes). Even rugged field engineers wearing water resistant gloves become quite uncomfortable after pulling the wet cables by hand a few times.

Pile Dynamics Inc has solved this problem by designing a Motorized Probe Deployment System (Automated Reels) that works with its CSL testing equipment, the Cross Hole Analyzer.

10 PIC Magazine • December 2011

In addition to sparing the testing engineer from constantly handling wet and often cold cables, the Motorized Probe Deployment System keeps the cables neatly organized on the spool, and allows the tester to gather information at a consistent speed ( this reduces the possibility of missed data points due to too fast a pull). The system is powered by either an eight hour duration battery or by an external 12 V power source.

In addition to the Cross Hole Analyzer and its Motorized Probe Deployment System, Pile Dynamics produces several other quality assurance and quality control products for the deep foundations industry. Its products are recognized throughout the world as the ultimate solutions for testing and monitoring of deep foundations. The company is based in Cleveland OH and has commercial representatives worldwide. For more information visit www.pile.com.

Lightweight Diverless System Offers Direct Control, Enhancing Safety and Efficiency T.D. Williamson (TDW) today announced the successful development and field deployment of the Subsea 1200RC Tapping Machine, its new compact remote-controlled subsea hot tapping machine. The system, which is extremely lightweight, allows hot tapping to be carried out from the safety of a Diving Support Vessel (DSV) or platform, resulting in significant safety benefits and improvement in operational control.

The past Subsea hot tapping of pipelines is performed for a variety of reasons, including tie-ins, pipeline repair, insertion of instrumentation, facilitating chemical injection or providing access for temporary isolation tools. The full process – which involves installing the hot tap assembly, performing the tap and recovering the hot tap machine – has invariably necessitated diver assistance.

This has meant that the potential for subsea hot tapping was inevitably shaped by human factors, namely the limits of where divers can operate.

Diver operations are limited to those taking place in a maximum of 300 meters of water depth, whereas a significant portion of existing subsea field infrastructure, as well as projected future developments, are in waters down to depths of 3,000 meters. Furthermore, the ability of divers

CanadaIndustry News Piling to operate effectively in shallow water can be affected by environmental factors, such as in wave breaking zones.

Lightweight, direct control diverless system The demands of deep water and the risks in shallow water have necessitated development of a completely diverless, remote-controlled system.

Responding to these demands, TDW has developed the Subsea 1200RC Tapping Machine, a remote-controlled hot tap machine.

“We are delighted to have developed this vital new technology,” says Mike Benjamin, vice president, Offshore Pipeline Solutions for TDW. “The most critical part of the hot tapping process is the point at which the drill penetrates the pipe, which has now been rendered diverless by the Subsea 1200RC Tapping Machine. The direct control and visibility from a laptop will revolutionize hot tapping, giving way to a more efficient and safer process.”

While the installation of the hot tap assembly and subsequent removal of the machine will still require diver assistance when a pre-installed tee is not present, the performance of the tap itself is remotely-controlled by a TDW technician onboard the DSV or platform. The system is a topside-driven hot tap machine with “passive Remotely-Operated Vehicle (ROV) interface,” which means that it is a stationary ROV with its hydraulics and control system attached to the Subsea 1200RC Tapping Machine, and operated from an on-board laptop.

The new subsea system has demonstrated the feasibility of conducting the critical tapping operation entirely by remote control. But the system offers more than just reduction in diver activity, the safety benefits of which are obvious. The further benefits of the new technology are that it offers total control and visibility of the tapping operation where there was none before. Built-in sensors allow continuous recording of actual pressures, temperatures, rotation and movement of the pilot drill and cutter.

They shed light on what is going on inside the enclosed space right at the heart of the cutting operation. The laptop-based program facilitates control remotely, rather than relying on the divers’ manual handling of the cutting process. The end result is a level of accuracy and quality that is not possible in diver-based operations.

Benefits demonstrated in first field operation The Subsea 1200RC Tapping Machine was tested and successfully deployed in 2011 on a tapping operation for a project in water depths of 91 meters. The tap size was 16-inch on an existing 28-inch gas pipeline.

TDW performed the operation from a DSV. The cutting operation itself lasted approximately two hours. The entire operation was conducted safely, while flow through the gas pipeline continued uninterrupted.

“We were thrilled with how well the Subsea 1200RC Tapping Machine performed,” says George Lim, business development manager for TDW. “The safety benefits and operational control of the device resulted not only in a satisfied customer, but it highlighted the enormous potential of this new technology.”

A bright future The benefits of using the Subsea 1200RC Tapping Machine in offshore projects are clear. The experience gained with this remote-controlled tapping machine will inevitably enhance the development of completely diverless systems covering all activities involved in a hot tapping operation.

12 PIC Magazine • June 2012

Moreover, these benefits will easily be extended to onshore operations.

A remotely-operated system automatically implies safe operations, for instance in emergency situations where pipeline intervention and repair takes place in dangerous environments following an incident.

TDW is especially pleased about the successful development of the Subsea 1200RC Tapping Machine because of its applicability for the Emergency Pipeline Repair System (EPRS) programs that the company offers to customers. EPRS involves planning emergency repair solutions before a failure occurs. Since the Subsea 1200RC Tapping Machine promises safer, faster and more efficient hot tapping, its value to EPRS is obvious.

About TDW Offshore Services The core business of TDW Offshore Services is to provide its customers with products and services they need to construct and maintain pipelines. The company’s world‐class engineering capability has resulted in numerous innovative products and services.

The company is a subsidiary of T.D. Williamson. A world leader in pipeline equipment and services, T.D. Williamson delivers a comprehensive portfolio of safe integrity pipeline system solutions for onshore and offshore applications, including hot tapping and plugging, pipeline cleaning, integrity inspection, pigging and non-tethered plugging pig technology for any pressurized piping system, anywhere in the world. n

Correction Notice While every effort is made to be as accurate as possible, we do make mistakes. Please note that the contact for Spiralco Inc. is Christian Côté.

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The Latest from

INTERMAT

What’s trending, new equipment and news from the three shows

By Vincent Jue, vice president, Soilmec North America Did you miss INTERMAT (Paris, April 2012), the ADSC EXPO (San

Here’s how it works. Both the hammer casing and the drop weight

Antonio, March 2012), or Con-Expo (Las Vegas, March, 2011)? I had the

have embedded sensors. The electronic control system continually moni-

opportunity to attend all three.

tors the drop weight position throughout the hammer stroke, both up

Exhibitors use these big equipment shows to unveil the latest develop-

and down, as the pile is being driven.

ments in their products and services. So if you want to see the important

During pile driving the control system calculates the velocity of the

advances in construction equipment, these shows are the place to do it. I

drop weight, and the energy input to the pile is calculated from the ve-

thought I’d share some of what I learned about the latest trends in equip-

locity change. Numerical read-outs show blows-per-minute, energy per

ment and tools for the piling and foundation construction industry.

blow, and total blows. All of the data can be transmitted to a laptop and saved for a daily record of pile driving productivity.

Remote Sensing and Control is Smarter

What’s great about this system is that it gives the operator control of

Dawson Construction Plant manufactures impact hammers, vibra-

the driving process that has never been available. The control system can

tors, sheet pile extractors, shackles, and other equipment for the piling

eliminate overdriving/underdriving and will drive to a specified energy/

industry. At INTERMAT, Dawson unveiled its new HPH6500e piling

blow. If a pile suddenly hits a soft soil layer and starts to run, the digital

hammer with a digitally controlled drop weight.

system automatically shuts down the hammer so that equipment isn’t

For contractors, this new hammer is going to make pile driving safer

damaged.

because there’s an automatic switch that shuts down the hammer if the

Foundation drilling contractors have access to similar advances in

pile is running. It’s also going to make pile driving more efficient because

electronic sensing and control. For example, Soilmec is offering now its

sensors measure the amount of energy being transmitted to the pile.

advanced Drill Mate System (DMS) on most of its drill rig models.

14 PIC Magazine • June 2012

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Call us today and let us help you find the right solutions for your applications.

www.eastrock.com

The DMS utilizes a full array of sensors for engine and various machine parameters with controlling software that help the contractor operate the machine most efficiently. The DMS standard functionality is as an operator-to-machine interface via a colour touch screen monitor in the cabin.

The DMS also monitors the production and quality of the installed product – whether it be the location and verticality of drilled shafts, or the production rate of jet-injected grout. Special monitoring and software packages are available for various technologies including large diameter pile, continuous flight auger, and cased auger pile installation, jet grouting, micropiles, and tie-back installation.

Some of the production parameters monitored by the DMS include depth, drilling rate, RPM, and thrust pressure; concrete or grout pressure and delivery; placement and verticality; etc. Soilmec even has a built-in online spare parts locator as part of the DMS. In addition, DMS can enable telematics. That is, all of the data collected by the DMS can be digitally transferred for processing, remote monitoring, jobsite reporting, troubleshooting, and planned maintenance. Data can be transmitted via radio GMS/GPRS, Wi-Fi, or satellite to a remote location, such as the Soilmec headquarters where Soilmec experts can help troubleshoot and support the jobsite activities.

Tier 4 is Coming There were a number of engine manufacturers at INTERMAT debuting their new engines to comply with U.S. Environmental Protection Agency Tier 4 final and European Union near-zero emissions regulations taking effect in 2014.

Cummins, for example, rolled out its QSB6.7 (140-300 hp) and QSL9 (240-400 hp) engines for Tier 4 final. These two engines are used in many types of construction equipment, including excavators, cranes, wheel loaders, compactors, and air compressors.

Over the past several years, Environment Canada has initiated a process to amend the Off-Road Compression-Ignition Engine Emission Regulations (SOR/2005-32) to maintain alignment with the more stringent Tier 4 emission standards of the USEPA for off-road diesel engines.

The amendments are expected to come into force for the 2012 model year.

In the mean time, in general, Canadian contractors buying equipment have three possible options for importing off-road diesel engines into Canada: • Engines sold concurrently in Canada and the U.S. under the U.S. EPA Tier 4 Flexibility provisions 16 PIC Magazine • June 2012

• Engines covered by a valid U.S. EPA certificate of conformity that are sold concurrently in Canada and the United States • Engines that will not be sold concurrently in Canada and the United States (i.e. so-called “Canada Unique” engines) but meeting current Canadian requirements.

Equipment is Reflecting Advances in Construction Techniques Contractors are constantly pushing the envelope on what can be constructed, how it’s constructed, and what equipment they’ll use to do it.

Many major advances in construction techniques are developed by contractors who see how something can be built better, faster, or cheaper.

Good equipment manufacturers are also on the cutting edge of designing equipment that will best serve the needs of their customers.

Present a new equipment capability to an innovative contractor, and new construction techniques are developed. Conversely, explore a new construction technique, and an equipment manufacturer will make the tools to build it.

How does this synergy between a builder and equipment manufacturer occur? Both Soilmec and Dawson Construction Plant are affiliated through corporate ties with construction companies (Trevi and Dawson Contract Piling, respectively). The major benefit is that both firms have built their equipment based on extensive direct feedback from jobsites and this has improved product development.

I’m of the opinion that companies that build solid field experience into their machinery have better equipment overall. Unfiltered access to information about machine performance, construction techniques, maintenance required, and other key factors is the key. Companies that have construction and manufacturing arms under a larger corporate umbrella have better access to this information. And one good way to convince yourself that your equipment supplier is up on his game is to check them all out, side by side at an equipment show.

At Your Next Equipment Show Bauma 2013 will be held in Munich in April 2013. Con-Expo follows in Las Vegas in March 2014. Hope to see you there and don’t forget to wear comfortable shoes because you’ll be doing a lot of walking.

Vincent Jue is a Vice President with Soilmec North America, manufacturers of Drilling and Ground Engineering construction equipment. Reach him at vjue@champion-equipment.com. n

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Don’t Get

Stressed

Let the user beware of the Beta Method

By Gerald Verbeek Verbeek Management Services

Beta Method Damage Classification

B (%) 100 80 – 99 60 – 79 < 60

Severity of damage Undamaged Slight damage Damage Broken

Pile that was not damaged according to the Beta Method

When driving concrete piles it is inevitable that some damage is done to the pile, simply because small cracks, which exist in the concrete even before the pile reaches the job site, will grow during pile driving. But, obviously the objective will always be that the pile damage is minimized and that the pile integrity is not affected. One way to demonstrate that is by load testing the pile once it is in the ground. If it passes the test the pile can be considered an acceptable foundation element. Another approach would be to subject the pile to a Low Strain Impact Integrity Test, but since this test does not detect all damage or provide any feedback

Drilling & Piles Ltd. Fort Macleod. Ab.

Ph: (403) 553-4084 Fax: (403) 553-2834 Trevor’s Cell: (403) 634-2152 Derek’s Cell: (403) 634-0544 info@westcodrilling.ca www.westcodrilling.ca

18 PIC Magazine • June 2012

on the pile’s bearing capacity, the outcome of that test is not necessarily conclusive. However, both tests have the same drawback - the damage assessment is done only when the pile is in place. A much more effective approach is a real-time pile damage assessment method applied during pile driving (as part of the pile driving analysis or PDA), such as the Beta Method introduced by Rausche and Goble in 1979, a method to “detect discontinuities or reductions in the cross section of the pile” and “to reach quantitative conclusions regarding the degree of section reduction at the discontinuity.”1 The concept behind this method is very simple - every hammer blow generates a stress wave in the pile. As the wave travels through the pile towards the pile toe, upward acting stress waves are generated by changes in pile impedance, by the soil resistance along the pile shaft and finally by the pile toe itself. When the upward wave signal suddenly changes, the magnitude of this change is analyzed to derive the impedance ratio (Znew/ Zold) or Beta. Assuming that the pile originally had a uniform cross section (and, therefore uniform impedance) over its entire length, this change in impedance is then assumed to reflect damage that has occurred in the concrete pile.

Over the years Rausche and Goble have published several equations for the Beta and even provided a damage classification scale, which is widely used in the industry, despite the fact that the authors clearly stated in their paper in 1979 that “there is no experimental proof available justifying the (…) classification”.

Given the fact that the Beta Method uses changes in impedance, the method is most effective in detecting horizontally oriented defects that affect the pile cross section (such as in the case of tension cracks), and can only detect vertically oriented material damage when there is a reduction in cross sectional area. Consequently, the Beta Method is best used during “softer” driving (which creates higher tension stresses in the pile, creating the tension cracks) because during “harder” driving damage is more likely near the pile toe due to the increase in the compressive stresses in the pile (to basically double the original value when driving into very hard material).

In recent years an alternative to PDA for pre-tensioned pre-stressed concrete piles was developed in Florida. Instead of mounting sensors at the top of the pile, sensors (both strain gauges and accelerometers) are cast in the pile at both the pile top and the pile toe (the so-called Embedded

Load Cells Data Collectors or EDC method). This method also allows pile damage assessment by monitoring the pile pre-stress levels where the gauges are located (the so-called Measured Pile Integrity or MPI Method). Since the EDC method has sensors mounted in the pile toe, it provides unique insight into the condition of the pile toe.

With now more than 400 piles with an EDC system installed in Florida alone, the Beta method was analyzed for pile toe damage assessment.

The initial outcome, which was published late last year2, was very concerning in that the Beta Method did not seem to be a reliable method for assessing pile toe damage. In a number of cases the Beta Method did not indicate any pile damage; however, when these piles were pulled based on the damage indication from the MPI Method, serious pile damage was observed in all cases. It was therefore concluded that while the data may not have been extensive enough to completely disqualify the Beta Method for assessing pile toe damage, there was sufficient reason to carefully re-evaluate the method.

This re-evaluation is now complete and the results will be published later this year in various papers co-authored by Goble. It involved both a theoretical review of the equation for the Beta and a practical review of the data sets available for piles with an EDC system installed. The theoretical review showed clearly that the Beta Method cannot be a reliable indicator of pile toe damage, and the practical review independently showed that the Beta Method is not a reliable indicator. Taken together it is clear that the Beta method should not be used to protect against pile toe damage.

Obviously, given the length of this editorial it is not possible to go into details as to how this conclusion was reached, but one thing is worth mentioning. In the original paper published more than 30 years ago Rausche and Goble clearly stated that there was no experimental proof to justify the damage classification, and yet the Beta Method damage classification became common practice. Countless piles were deemed to have been installed without any damage, because we trusted a number, even though there never was any justification for that number. The bottom line is clear: user beware of the Beta Method, especially when it comes to toe damage in concrete piles.

Footnotes 1

2

Rausche, F. and Goble, G.G., “Determination of Pile Damage by Top Measurements,” Behavior of Deep Foundations, ASTM STP 670, Raymond Lundgren, Ed., ASTM, 1979, pp 500-506.

Verbeek, G., Middendorp, P, December, 2011. Determination of Pile Damage in concrete piles, DFI Journal, Vol. 5 (2), pp 23-29 n

To get the most accurate and reliable pile test results, count on quality-built vibrating wire load cells from Geokon, Inc. The World Leader in Vibrating Wire Technology™ www.gkmconsultants.com www.geokon.com

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Piling Industry Canada • June 2012 19

Canada

Upgrading Gear Westco Drilling & Piles Ltd. invests in a second rig In order to keep up with the growing demand of pilings, Westco Drilling & Piles Ltd. has just recently purchased their second rig. The 2006 Watson can drill to a depth of 80 feet and diameter of 12 feet. With this new addition the company hopes to better serve southwestern Canada including Alberta, B.C. and Saskatchewan. Added to their present Highway Drill HD60 rig, this gives us more capacity and flexibility. The team has also expanded to meet these needs and they are excited to see what the year will bring.

Westco Drilling & Piles Ltd. are presently seeing a lot of activity in southern and central Alberta due to a large investment in electrical generation infrastructure and alternate energy development. Over the past three years a large percentage of their work has been servicing these demands and although the economy has been generally depressed this sector has remained strong. We are now seeing resurgence in the local (Albertan) economy and the electrical infrastructure market is continuing to grow.

The Alberta-based company has a number of large clients who continue to use them on a large number of their projects throughout the province and are now witnessing an increased demand from more conventional construction clients.

This increase in activity is not only providing more work but also often requiring larger equipment for more demanding projects. With Westcoâ&#x20AC;&#x2122;s new rig we are now more able to meet these demands.

Westco Drilling & Piles Ltd. continues provide full pile service including engineering, as well as the labour and equipment required for the layout, removal, or stock-piling of tailings, tying and placing re-bar cages and the supply and placing of concrete.

Piling in itself requires intricate engineering, especially in electrical substations, as the foundation design is affected by soil structures, frost heave, water table and the structural load. As with other types of foundations, the purpose of a pile foundation is to transmit a foundation load to a solid ground to resist vertical, lateral and uplift load. Westco Drilling and Piles Ltd. is able to provide this engineering for their clients. n

20 PIC Magazine â&#x20AC;˘ June 2012

Platinum Grover “The Piling Connection”

TM

Servicing Canada and USA

Canada

Control of Contaminated Groundwater Using sealable joint steel sheet piling, contaminants are prevented from moving off site

By M. Le, C3 Environmental Limited, R. Jowett, Waterloo Barrier Inc. Low permeability containment walls are increasingly used in groundwater pollution control and remediation. Containment enclosures minimize or eliminate the need for contaminant plume control by groundwater pumping and water treatment. Contaminants are prevented from moving off site while site control activities, such as source removal and plume remediation, are carried out in the isolated subsurface environment inside the walled enclosure.

New passive and semi-passive treatment technologies for the interception and in situ treatment of groundwater contaminants provide alternatives to conventional pump and treat approaches. In systems such as these, containment walls can be used to direct plumes into subsurface treatment zones containing reactive media. This article describes the development and recent applications of sealable joint steel sheet piling for groundwater containment wall construction.

bulk wall hydraulic conductivities of 10-8 to

the ground, preventing the build-up of com-

10-10 cm/sec could be achieved; this was well

pacted soil within the cavity. After driving, any

below the 10-7 cm/sec limit normally required

loose soil remaining in the cavity is jetted clean

by regulatory agencies for vertical barriers at

with pressurized water. A sealant injection line

contaminated sites. A roll-formed manufac-

is then lowered to the base of the open cavity

tured version of the sealable sheet piling be-

and a low permeability grout is emplaced from

came commercially available in late 1993 and

bottom to top.

is now in use at more than 80 contaminated

Potential leak paths through the Barrier are

sites in North America.

limited to the sealed joints and, therefore, the

Standard pile driving equipment and tech-

joints are the focus of quality assurance and

niques are used to install the Barrier. A foot-

quality control procedures (QA/QC). The

plate at the base of the sealable cavity displaces

vertical alignment of piles is monitored dur-

soil laterally as the steel sheets are driven into

ing driving, and the flushing and probing of

The Waterloo BarrierÂŽ The Waterloo BarrierÂŽ is a steel sheet piling system that incorporates a sealable cavity at each interlocking joint (Figure 1). It was developed in the late 1980s by researchers at the University of Waterloo for the purpose of constructing secure test cells for controlled releases of DNAPL chemicals in a shallow sand aquifer at Canadian Forces Base Borden near Alliston, Ontario.

Several available containment wall technologies were investigated and found to be cost-prohibitive for the construction of small scale, closed test cells, or they were found to be insufficiently watertight. Hydraulic testing of prototype sealable joint sheet piling in numerous closed cells at CFB Borden and an industrial site near Sarnia, Ontario, indicated that 22 PIC Magazine â&#x20AC;˘ June 2012

Figure 1. Waterloo Barrier Sheet Pile.

Canada

Photo 1. Containment wall installation along Welland River.

the sealable cavities provides documentation regarding the ability to inject sealant the full length of the cavity. Records of grout volume, pumping time and starting depth provide assurance that the entire cavity has been sealed.

Several types of sealants have been developed to meet specific project requirements. These include clay based grouts such as bentonite and attapulgite, cement based grouts modified with expanding agents, epoxy polymers, urethane polymers and inflatable mechanical packers. Grout selection is governed by the required service life of the installation, chemical compatibility with groundwater contaminants, and whether or not the piling has to be

ect was developed through a partnership between the City of Welland and Walker Environmental Group.

As an essential component of the remediation, a Waterloo Barrier® containment wall system totalling approximately 4,400 square metres was completed at this former landfill site in January 2012. The Waterloo Barrier® will prevent the migration of contaminants to the adjacent Welland River and enhance the leachate collection system (Photo 1). The wall was driven

Photo 2. Sealed interlocking joints.

to refusal through fill and stiff soils comprised of sand, clay and till using a crane, hydraulic impact and vibratory hammers.

A proprietary cementitious based grout (WBS301 grout) was used to seal the interlocking joints due to its low permeability, high density, and high resistance to chemical degradation (Photo 2). Subsequent phases of the

removed from the ground after site cleanup.

The Waterloo Barrier® has proven its versatility in differing geological conditions and in a wide variety of applications. However, as with all steel sheet pile walls, the Barrier is not suitable for use in extremely dense or rocky soils, and in densely populated urban areas the noise and vibration from pile driving equipment may be a concern. Typical applications include containment to limit offsite migration or protect waterways, the construction of subsurface in situ treatment systems, and structural support and dewatering for the excavation of contaminated soils. Examples of recent Canadian projects are described in more detail.

Former Atlas Landfill, Welland, Ontario The Atlas Landfill Remediation Project began in the second quarter of 2011. The projPiling Industry Canada • June 2012 23

Canada

Photo 3. Temporary cutoff wall served as excavation support.

WEATHERALL DOCK AND DREDGE INC.

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24 PIC Magazine • June 2012

work at the former landfill site entailed the installation of wetland ponds, leachate collection, groundwater monitoring and capping systems.

The Atlas Landfill Remediation project was a success that turned a $15 million liability into a revenue generator for the city of Welland. The landfill is back in operation for a period of about seven years after which the property will be redeveloped for recreational use. In October 2011, the project was selected by the Canadian Urban Institute as a finalist for an environmental Brownie Award.

Former Commercial Site, Newmarket, Ontario A temporary Waterloo Barrier® cutoff wall was installed along the Holland River at a former commercial site, in November 2010. The purpose of the cutoff installation was to facilitate the removal of the hydrocarbon impacted soils below and along the river bank.

The cutoff wall served as the excavation support system (shoring system) that allowed the removal of contaminated soils approximately two metres below the river bed (Photo 3). Due to the low permeability of the Waterloo Barrier® system, the wall also served to minimize the amount of water entering into the excavated area, significantly

Canada

Photo 5. Sealing the interlocking joints.

Photo 4. Installation of the containment wall along property line.

ONTARIO

Interpipe Inc. is a steel pipe distributor of new reducing the costs of dewatering water structural steel pipe. We have two andandused treatment on the project. At the same time, large stocking locations of Seamless, ERW, potential free phase products and silty soils Spiralweld and DSAW pipe. were prevented from entering the river during

LOUISIANA 3320 3607 I-10 Miles FrontageRoad, Road RR#3 Port Allen, Louisiana Mount Hope, Ontario 70767

L0R 1WO

Toll Free: (877) 468-7473

the excavation process.

Interpipe Inc. is a steel pipe distributor of new and used structural steel pipe.

We have three two Bentonite clay based grout 3” was selected to andin used structural of steel pipe.thicknesses We have OD – 48” OD a variety wall large ERW, large stocking stocking locations locations of of Seamless, Seamless, ERW, seal the interlocking joints soare that stocked the temin Spiralweld both locations. and DSAW DSAW pipe. pipe.

Spiralweld and porary wall could be removed easily after the backfilling process. Once the clean fill was 3” –48" 48”OD ODininaavariety varietyof ofwall wallthicknesses thicknesses 3" OD OD –min yield seamless pipe for placed in the excavated area, Piling the cutoffPipe wall 80,000 are in all both locations. are stocked stocked in three locations.

Micro Piling. was extracted with similar sheet pile driving Piling equipment and the river bank was restored to Piling Pipe Pipe 80,000 80,000 min min yield yield seamless seamless pipe pipe for for Micro its original condition.

Micro Piling.

Piling.

Seamless and ERW pipe for Driven Piles, Seamless and pipe for for Driven Driven Piles, Piles, Screw Piles and Drill Piles.

Seamless and ERW ERW pipe Brownfield Redevelopment Site, Toronto, ON

Screw Screw Piles Piles and and Drill Drill Piles.

Piles.

Large pipe for Driven Caissons.

A Waterloo Barrier® containment wallDiameter was Large Diameter pipe for for Pile Drivenor Pile or Large Diameter pipe Driven Piles or Caissons.

Caissons. installed at a brownfield site in April 2011 to prevent the migration of the chlorinated solvent impacted groundwater onto the adjacent property.

Prior to the installation of the containment wall, the levels of noise and vibration from the sheet pile driving were assessed to ensure minimal disturbance to the surrounding urban area could be achieved during construction. The sheet piling was driven along the site property line and was anchored in a confining layer approximately three metres below ground surface (Photo 4). Once the sheet piling was installed, the interlocking joints were cleaned and sealed with cementitious grout (Photo 5).

Subsequently, the foundation wall of a new building was cast against the installed cutoff wall and the entire property was redeveloped into an active commercial site. n

Local: (905) 679-6999 ONTARIO 3320 Road, RR#3468-7473 TollMiles Free: (877) ONTARIO MountMiles Hope,Road, Ontario 3320 RR#3 Fax: (905) 679-6544 L0R 1WO Mount Hope, Ontario L0R 1WO Local: (905) 679-6999 Local: (905) 679-6999 Toll Free: (877) 468-7473 Toll Free: (877) 468-7473 Fax: (905) 679-6544 QUEBEC Fax: (905) 679-6544 805 1 ère Avenue

QUEBEC Ville Ste. Catherine, Quebec QUEBEC 805 1 ère Avenue J5C 1C5 805 ère Avenue Quebec Ville 1 Ste. Catherine, Ville Ste. J5C 1C5 Catherine, Quebec J5C 1C5 (450) 638-3320 Local: Local: (450) 638-3320 Local: (450) 638-3320 514-0040 Toll Free: Toll Free: (888) (888) 514-0040 Toll Free: (888) 514-0040 Fax: (450) 638-3340 Fax: (450) 638-3340 Fax: (450) 638-3340

www.interpipe.com Piling Industry Canada • June 2012 25

Canada

Combining Forces Tadano Mantis partners with Bermingham Foundation Solutions Tadano Mantis heavy duty telescopic boom crawler cranes have a long history operating in foundation projects, and are commonly seen on job sites tending large drill rigs and piling cranes or handling vibratory hammers to install and extract piles or caissons. Recent cooperation with both foundation equipment manufacturers and customers have led to new applications of the Tadano Mantis crane with lead systems and impact hammers. Icanda Corporation based in Laval, Quebec has recently rented a 77 ton Mantis Model 15010 from Cropac Equipment, Mantis’ dealer in Quebec and Ontario, along with 78 feet of Bermingham Foundation Solutions L-15 ver-

D.A. McIntyre Construction Ltd.

Over 40 Years of Reliable Quality Service • Sheet Piling & Retaining Walls • Bridge Construction & Repair • Pipeline Scour Protection • Pile Driving of All Types • Erosion Protection

#203, 17205 - 106 A Avenue Edmonton, Alberta T5S 1M7 • Canada Phone 780-484-6333 • Fax 780-987-4098 mcintyremap@canadasurfs.ca

26 PIC Magazine • June 2012

tical travel leads, a Bermingham B-21 Diesel Hammer and an HHH-12 hydraulic spotter.

Icanda will be utilizing the Mantis Crane and Bermingham lead system to drive pipe piles in varying batter configurations for a bridge foundation near Chicoutimi, Quebec.

The Mantis 15010 was identified as an ideal piling crane by Icanda because of the heavyduty construction of the crawler crane coupled with the flexibility of the telescopic boom, the integrated lead and hammer controls that are offered as a standard option on the crane and the fast self-erecting capabilities of the crane and pile driving system. The pile driving lead interface option on the crane includes an integrated control console, spotter lugs, hydraulic valving and quick coupler panel. Included control functions for lead and spotter winches and cylinders to adjust batter, lead height, pile gates and hammer starter and throttle controls. Tadano Mantis and Bermingham Foundation Solutions have cooperated together for the past two years to develop a vertical travel lead (VTL) piling system optimized for the Model 15010 crane which can offer piling at radii up to 34’-4” and batters up to 4:1 in all directions with piles weighing up to 5,200 lbs.

The crane and VTL system was displayed in a pile driving configuration at ConExpo 2011 in Las Vegas and then as a drilling system – with an Atlas Copco QL120 down hole hammer at the recent ADSC show in San Antonio in March.

Upon arrival at the job site, the Mantis crane quickly goes to work unloading and self-erecting its counterweights, then assembling and erecting the vertical travel lead system, which quickly attaches to the pre-installed boom tip adapter. The crane, lead and hammer system is completely assembled and erected in under a days time and is ready to go to work driving piles. The initial job that Icanda will be using the crane for will consist of driving 40, 14-inch

and 16-inch piles that will be spliced to a maximum length of 93 feet. The piles will be driven inside of coffer dams below grade at batters set up by the hydraulic spotter, so no template is needed for the piling job. As quickly as the piling system can be rigged up, it can also be dismounted from the crane. Thus the Mantis can effectively go from a piling crane to a lift crane in very little time. Tadano Mantis cranes are suited for much more than lifting – the cranes have full load chart pick-and-carry capabilities, full power booms that can telescope the entire load chart, high powered Cummins diesel engines and performance matched hydraulics allow for both superior travel performance, as well as the ability to perform multifunction crane operations and to power auxiliary tools. Other standard options well suited toward foundation applications include controlled free-fall winches, a 14,000 lb-ft torque boom mounted auger drive, and a FOPS for the standard cab.

Tadano Mantis has worked with foundation contractors in support of adapting all sizes of Mantis cranes for various foundation jobs and applications. Over the years a variety of lead systems for either pile driving or drilling along with auxiliary hydraulic circuits have been adapted to Mantis cranes from 18 ton through 100 ton capacity. Serving the foundation industry with telescopic boom crawler cranes designed for the heavy duty applications seen by foundation contractors remains a key aspect in the present and future development process for Tadano Mantis Corporation. n

Tadano ManTis

Heavy duty Telescopic Boom Crawler Cranes 15010 • 77 Ton Capacity Shown with Bermingham Foundation Solutions: L-15 Vertical Travel Leads - 88 Feet B-21 diesel Hammer HHH-12 Heavy duty Hydraulic Spotter

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20010 • 100 Ton Capacity

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Canada

Offering More Irving Equipment provides Atlantic Canada and beyond with service and skills

For over 125 years, J. D. Irving, Limited’s focus has been on providing quality service and products to customers around the world. With over 15,000 employees, the company has business units in forestry and forest products, transportation, shipbuilding and industrial marine, retail and distribution, construction services and building materials, specialty printing and translation and consumer products.

Irving Equipment was established over 50 years ago by J.D. Irving, Limited as a family owned company with operations in Canada and the United States. Approximately 80 per cent of Irving Equipment’s current work occurs in Canada, although they also have cranes located throughout the United States. The success of Irving Equipment has relied on investing in the latest technologies and instilling employees with a sense of ownership.

During the early years of the company’s existence, the majority of work was executed for the Irving family during large industrial projects. However, in recent years the vast majority of work has been executed for external customers. An expectation for growth necessitated an expansion from an internal (Irving work) to an external focus. In addition, the company also expanded outside its traditional Atlantic Canadian markets.

The transition of the company from an internal focus to an external focus means that assets are no longer purchased only during periods in which the Irving family is executing a large industrial project. This has resulted in an increased emphasis on strategic planning, sales and marketing.

28 PIC Magazine • June 2012

In 1987, Irving Equipment revolutionized the crane industry when they created the first three-dimensional lift planning system, now known as CraneCAD™. Over the past 20 years the company has continually updated and adopted the technology to today’s market, which has helped the software produce over 10,000 drawings.

Big or Small As Atlantic Canada’s largest crane rental and pile driving contractor, Irving Equipment has the resources to complete projects efficiently and effectively, regardless of size. One of the biggest benefits of working with Irving Equipment is gaining access to an exceptional workforce, experienced operators and their talented team of in-house engineers. As one of the only crane companies to be registered ISO 14001:2004 and ISO 9001:2008, they make sure their assets are maintained to meet those standards.

Project Managers have handled some of the largest and most complex industrial projects in the region, which has given them the experience and skills to plan and tailor a solution for any job.

Significant areas of growth during the next five to 10 years include: wind power (installation and maintenance), mining and repair of aging infrastructure. n Piling Industry Canada • June 2012 29

United States

Cross Over Flatiron uses Poseidon 2-7’ barges on the Lake Champlain project Flatiron, one of the nation’s largest transportation and infrastructure contractors, was awarded a $69.6 million contract by the New York State Department of Transportation to construct a bridge that will connect Crown Point, N.Y., and Chimney Point, Vt. Flatiron was the low bidder of eight contractors vying for the contract. The project is the company’s first in New York.

The original 80-year-old bridge was demolished in December because inspections deemed it unsafe. The new bridge, spanning 2,200 feet over a narrow stretch of southern Lake Champlain, will be constructed with conventional steel girder approaches and a modified network tied-arch main span. The main span will be assembled on land and then floated and hoisted into position.

Flatiron is used the Poseidon II 40’ & 20’-7’ Portable Sectional barges on the Lake Champlain project.

Construction has been completed and New York State residents can finally cross over the Burlington, VT without traffic delays. Eighty percent

30 PIC Magazine • June 2012

of the project’s total cost was funded by the U.S. Federal Government.

The balance of funding was split evenly between the states of Vermont and New York.

“We are excited to have this opportunity to work in New York and look forward to more opportunities in the area,” says Tom Rademacher, Flatiron CEO. “We anticipate a successful partnership with NYSDOT.” Flatiron, with a construction volume of $1.04 billion in 2009, is one of the leading providers of transportation construction and civil engineering in North America. Its core competencies include major bridge, highway and rail projects. Flatiron also operates as a contractor in publicprivate partnership projects. Founded in 1947, the firm is a subsidiary of HOCHTIEF, one of the world’s leading international construction service providers.

Poseidon sells and rents portable sectional barges to the bridge, marine and heavy highway construc tion contractors. You can find out more information on their web site at www.poseidonbarge.com. n

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Dans une entreprise où le service est l’élément clé pour la réussite de votre projet – vous ne pouvez vous contenter du minimum.

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United States

Test Design River work on New York’s Tappan Zee Bridge now underway

By Melanie Franner

When construction eventually begins on the new, multi-billion dollar

explains. “The rock surface is approximately 200 feet below surface in

Tappan Zee Bridge Hudson River Crossing, it will serve to re-affirm the

one area and no rock 700 feet below the surface in another area.”

significance of this major arterial roadway as an economic engine to the northeast United States.

Preliminary Work Underway

“This artery is a connector to New York, New Jersey, Connecticut and

To identify the potential impacts associated with the project, the New

the whole of the northeast corridor,” states Andy O’Rourke, director of

York State Department of Transportation and the New York State Thru-

the Tappan Zee Project, Public Information. “The next nearest crossing

way Authority have issued a Draft Environmental Impact Statement

upriver is 50 miles away.”

(DEIS). The Final Environmental Impact Statement (FEIS) is expected to

Thanks to the hard work of New York State Governor Cuomo, the Tap-

be completed this fall, whereupon request for proposals will be accepted

pan Zee Bridge Crossing has been re-scoped from its original $16 million

from the four firms that have made the short list of qualified candidates.

design (that would have included 15 miles of commuter and CRT rails on

As part of the EIS, the authorities have contracted for some “Smart

either side) and fast tracked by President Obama into an estimated $5.2

Early Work” to ascertain subsurface conditions and obtain better infor-

design/build project that involves the creation of two separate bridges,

mation on foundation capacities and installation methods. The Geotech-

each of which will span approximately 3.1 miles.

nical Investigation involves a series of 72 separate drilling operations

According to O’Rourke, the foundation work required for the project is

where core samples were removed and analyzed. These samples consisted

one of the largest components, accounting for approximately 30 per cent

of mud, sand, shale and bedrock.

of the estimated cost.

“The soil samples are being collected to better determine the eleva-

“It’s critical that we get this information right,” he notes.

tion to rock and soil and rock characteristics,” explains Edwards, who

Kristine Edwards, Tappan Zee Bridge Design Development Engineer

adds that the soil demonstration program will enable the design/build

for the New York State Department of Transportation on the Tappan Zee

proposers to have access to more accurate information so that they can

Hudson River Crossing project, concurs.

better define their bids. “The pilings and foundation is the element of

“The foundation work required on this project is one of the more chal-

work within the project that had the highest degree of uncertainty in the

lenging aspects of the project due to the existing soil conditions,” she

preliminary design phase.”

“The soil samples are being collected to better determine the elevation to rock and soil and rock characteristics,” explains Edwards, who adds that the soil demonstration program will enable the design/ build proposers to have access to more accurate information so that they can better define their bids.

32 PIC Magazine • June 2012

United States

The need to correct substandard structural, operational, mobility, safety and security features of the existing bridge was also taken into consideration, as was the need to overcome the existing bridge’s inadequacy in meeting current bridge and highway standards (e.g. lane and shoulder widths).

Another “Smart Early Work” is a Pile Installation Demonstration

Replacing an Icon

Project, which was undertaken to determine the load capacity of seven

The existing Governor Malcolm Wilson Tappan Zee toll bridge was con-

piles at four strategic locations in the future path of the new bridge. This

structed in 1955. At the time, it was designed to withstand a peak traf-

information is of extreme importance to help the RFP respondents determine exactly how many supports and at what depth and distance the footings need to be placed.

According to Edwards, this work is currently underway and the results of this preliminary work will soon be revealed to the RFP short-listed candidates, with their subsequent bids expected to be submitted sometime this fall.

Minimizing Environmental Impact The project will also include environmental stewardship initiatives designed to avoid and minimize impacts to neighbourhoods, environmental resources, historic sites, fish species, important habitat and other sensitive areas and resources.

One example of the project’s environmental stewardship is the innovative mitigation measure of creating a “bubble curtain,” which generates a dense shower of underwater bubbles that surround a specific construction element, such as a bridge pile, to help protect fish and other marine life by dampening sound during pile driving.

Another innovative environment stewardship initiative being proposed would protect the endangered peregrine falcons that nest in boxes on the existing bridge. Prohibiting construction activities to heights greater than 26 feet above the roadway or within 100 feet of the piers over which nesting boxes are located are two possible ideas, as is marking the tops of heavy equipment with flags to deter peregrine falcons from landing on them during nesting period.

fic load of 100,000 vehicles a day. Already, however, traffic has grown to approximately 138,000 vehicles per day or some 50 million cars a year.

“One of the problems with the existing bridge is that it has no emergency lane, median or shoulder so that all it takes is one accident to stop traffic completely,” explains O’Rourke. “The decision to build the new crossing comes down to safety and economics.”

Other alternatives to the new bridge were considered during the last 12 years but eventually, rehabilitation of the existing bridge was considered to be too disruptive and costly. Additionally, rehabilitation wouldn’t enhance traffic mobility or reduce congestion. The need to correct substandard structural, operational, mobility, safety and security features of the existing bridge was also taken into consideration, as was the need to overcome the existing bridge’s inadequacy in meeting current bridge and highway standards (e.g. lane and shoulder widths). The decision to build a new bridge was also affected by the extensive and costly maintenance programs currently affiliated with the existing bridge.

Towards a Better Future Although actual construction work on the new Tappan Zee Bridge Hudson River Crossing has yet to begin, extensive preliminary work has been well underway for several years now. The results of all of this preliminary work will eventually be evident in the design and construction of the new crossing – which is anticipated to provide improved safety, structural and operational features that will far outweigh those of the

Not all of the environmental stewardship initiatives involve local habi-

existing bridge. And, when the new crossing is finally unveiled, it will

tat or endangered species. Improving the operational deficiencies of the

include a pedestrian walkway, bike path, scenic portals for viewing vistas

existing bridge is one such example. This can be achieved through the use

– and it will be designed to accommodate rapid transit if and when the

of features to reduce pollutant emissions (e.g. three highway-speed toll

need arises.

lanes to replace the two existing 35 mph lanes to reduce congestion and

“We’re building this bridge for today, tomorrow and the future,” con-

idling emissions).

cludes O’Rourke. n Piling Industry Canada • June 2012 33

United States

Flying Right X52 Kirkwood to Trienda 138kV Island Span Fix Every construction job starts long before the mobilization of equipment, field personnel and materials. It starts with the end vision and a few experienced minds working on the way to get there. The resources that every construction veteran takes to work each day start to fill in the gaps and solve the puzzle of the project.

Things not left to chance, but things not illustrated in the specs either. These are the things in every job dependent on talent, experience and knowledge.

In Calendonia Wisconsin, American Transmission Co. required installation of replacement transmission structures across the Wisconsin River via Pine Island and adjacent islands. Described in the engineer’s report as “generally vacant”, the area’s ground surface is “typically grass covered with dense trees”.

There is no access to the islands, and the report further describes the topography as “varied”.

A span of 1750 feet would be covered by installation of two 160 foot H-Frame Steel structures and five light duty structures stepping down to accommodate the river crossing.

The larger structures would each require two 45 1/4” diameter steel caissons, driven to depth of 36 feet. The smaller structures would each be set on two caissons varying from 161/4” - 20” in diameter, driven into the ground to depths of 20 to 25 feet.

A familiar construction problem must have immediately occurred to the personnel involved in the project in the early planning phases: How to access?

ATC’s environmental policy which includes a section, “Impact Reduction”. It reads, “Reduce environmental impacts of construction, operation and maintenance through the use of innovative practices, cost-effective technologies, and, where appropriate, environmental mitigation and enhancement.” Per ATC’s commitment, they dismissed construction bridge access as too impactful, not to mention costly.

Perhaps winter conditions could improve access by providing frozen terrain and lower wa34 PIC Magazine • June 2012

ter levels. Unfortunately the winter of 2012 did not comply.

So how to access?

“Helicopter.”

As is most often the case in construction challenges, phones rang, e-mails flew, and the people tasked with making it work called on experience and contacts to find out, “Who done it, how’d they do it and how’d it go?” After several meetings with Erickson Air-Crane, Portland, Ore., ATC’s project team and Henkels & McCoy decided a viable solution would be helicopter construction.

When the call came in from Henkels and McCoy, American Piledriving Equipment had a few air crane jobs under its belt. Says Ameri-

Screaming / hand signals were your only means of communication between the crew once the air crane was in position. can Piledriving Equipment Midwest Branch Manager Ed Corbett, “We had worked with several contractors on jobs where the only way in was a flying vibro (Vibratory pile driver/ extractor). APE had developed what we call a “Helitemplate”, or skid, to hold and place the power unit while the vibratory pile driver is retrieved. The legs are on rams that are hydraulically powered to adjust for varying ground conditions often found in low access areas. A gantry attached to the top of the power unit provides a sleeve, or gate, for the caisson, operated with hydraulics to adjust placement, with manual adjustments for fine tuning.”

Selected for installation of the steel caissons in the mostly sandy soils found in the boring logs was an American Piledriving Equipment’s J&M 28-35. Mobilization was scheduled for the end of January.

“Damned good planning,” says Paul Ives, Henkels & McCoy’s project manager, “Once you mobilize that bird in, you want to get to work, you want to keep it at work until the job is done.”

Henkels and McCoy marked the timber mats so the ground crew could line up the components as the set-up flew in. Next the helitemplate mounted power unit was dropped into place, lined up so the template would place the caisson, to be refined to acceptable tolerance by the hydraulic gantry. The caissons would be lifted into place and the air crane would fly off to retrieve the J&M 28-35 vibratory pile driver from the laydown site across the river. The Vibro would suspend from the helicopter on specially designed sling to prevent spin, and then lowered and attached to ears pre-mounted on the caisson. The vibro caissons were driven to variable depths with approximately six to seven feet of reveal protruding from natural ground line. These were driven to within approx. 18” of the top of the helitemplate, while supported by the air crane above. Then the ship would detach to allow the J&M 28-35 to free drive the remaining required depth. Alignment and proper spacing of the caissons were critical and numerous fine tuning adjustments for plumb and cant had to be in continuous monitor as driving initiated.

A capability called “Power-Beyond” facilitated use of all the hydraulics via a single power unit and eliminating the need for an auxiliary power unit. The Power Beyond option, available on all J&M power packs, uses the clamp manifold to additionally power an auxiliary hydraulic circuit containing its own hydraulic control valve bank while maintaining the use of the clamp circuit. Says American Piledriving Equipment Engineer Scott Gray, “The APE Helitemplate set-up needed to use the legs to get the template level as well as position the gantry. We did not want to bring in an additional power unit so the Power-Beyond allowed the Vibro, the clamp manifold, the hydraulics of

United States the template, and the self-leveling feet of the

der the ship, 40 plus year old men looked like

“We were impressed,” says the job Gen-

skid to power from one circuit.”

teenagers that had just stepped off a wet n’ wild

eral Foreman Scott Mueller. “The APE setup

On the ground, the crew worked under

roller coaster ride.

worked like we expected it to.”

the unfamiliar phenomenon of “rotor wash”

There were several safety matters that had

and the pressure of one fleeting week for the

to be addressed. There were adverse conditions

A total of 16 caissons were installed using

air crane mobilization. January in Wisconsin

with recent snowfall (crew wore certified ski

was a little kinder than usual in 2012, but cold

goggle to protect the eyes), potential risks of

conditions nonetheless. Wind speed exceeded

flying debris (crew wore certified ski helmets

70 mph stabilized. This was a crew that had

for head protection), slick mats from the icing

never worked with the likes of a heli-instal-

regarding footing (Crew wore ice cleat over-

lation. Henkels and McCoy’s Chris Forsythe,

shoes), extreme wind chills created by the wash

Construction Manager, Scott Mueller, Trans-

(proper clothing layering, face masks, gloves),

mission Line Superintendent, and Jim Jacobi,

and extreme noise levels (crews utilized avia-

ATC Construction Coordinator, were the only

tion style ear phone in conjunction with ear

three with previous experience. They had tried

plugs to deter the extreme noise). Scream-

to explain the magnitude of the wash to the

ing and hand signals were the only means of

crews, but it was only to be experienced first-

communication between the crew once the air

hand to get a real understanding. On the first

crane was in position

flight as the ship emerged in the distance with

Talent, experience and knowledge accom-

the power pack in suspension, the crews were

modates for new circumstances. Such was the

overwhelmed with anticipation and pure awe

case with work under a 16,500 pound payload

at the enormous size of such a machine hov-

helicopter. From contractor to equipment sup-

ering directly above them. The initial wall of

plier, air crane operator to the crew in the cold

& McCoy, helicopter crews and the airboat

wash was overwhelming to them; their talent

mud and rotor wash, the challenges of delivery,

captain for their hard work,” said ATC Project

mixed with adrenaline took control. After set-

coordination, installation were met with qual-

Manager Doug Berton. “The project went in

ting the first alignment of the power unit un-

ity work.

service two weeks early thanks to them.” n

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the Ericson air crane and APE helitemplate method. For the accessible installations, drilling equipment was used. All told, 16 caissons were installed for the seven transmission structures.

With the foundations in place, the two pole H-structure configuration were erected via a bolted flange type assembly. Erickson provided three lifts for installation of each. One lift each for the legs, and then the top H sections consistent with the remaining pole tops and the cross arm, were all flown out pre-assembled. These units were mated and bolted at the site by the ground crew working from aerial cranes. The smaller five structures were flown in single lifts.

“I’d like to thank the project team, Henkels

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sales@pile.com Piling Industry Canada • June 2012 35

International

Mind The Gap Threading Piles through London’s Congested Underground

By Alexander Nikolic, C.Eng., Associate Director, Buro Happold Ltd, U.K. Angelo Fasano, C.Eng., Senior Engineer, Buro Happold Ltd, U.K. Jim Cook, C.Eng., Director Buro Happold Ltd, U.K. Yvonne Ainsworth, C.Eng. Construction Project Manager Bauer Keller JV, U.K. This article was originally published in DFI’s magazine, Deep Foundations, March/April 2012 issue. DFI is an international technical association of firms and individuals involved in the deep foundations and related industry. Deep Foundations is a member publication. To join DFI and receive the magazine, go to www.dfi.org for further information.

The Denmark Place project is the redevelopment of a central London site on Charing Cross Road, which coincides with the broader redevelopment and upgrade of the adjacent Tottenham Court Road underground station.

Another part of the upgrade is the construction of the proposed Crossrail tunnel and station works in the area. Tottenham Court Road London Underground Station is serviced by the existing Northern Line route, and the transformation will enhance its capacity to serve the expected 200,000 daily passengers.

36 PIC Magazine • June 2012

The Crossrail tunnel is a new major railway link under central London, one of the largest infrastructure projects in the U.K. for decades.

The extreme congestion below ground called for an intricate foundation design solution and the use of an unusual D-shaped pile.

The Denmark Place mixed-use commercial development, also termed the over-site development, occupies a prime site in central London. The parcel of land measuring approximately 80 metres by 40 metres is located on Charing Cross Road, just south of the

landmark Centrepoint building at the junction between Tottenham Court Road and Oxford Street. The proposed development will include a significant basement substructure (approximately 12.0 metres in depth) and a 12-storey above ground building superstructure.

Site Congestion Although the Denmark Place site is owned by a private developer, the footprint is effectively dissected by one of the two proposed Crossrail tunnels. The requirement for a new

International escalator provided additional challenges to the Buro Happold design team as the entire western portion of the site is occupied by the proposed 30.0 metre escalator box. A further major constraint facing the design team included the presence of the existing Northern Line station tunnels in extremely close proximity to the western site boundary. In turn, the southern site boundary is occupied by London’s “Tin Pan Alley” on Denmark Street, a major music hub since the 1920s, which retains a protected architectural and cultural status.

Although the project included many complexities and challenges, the focus remained on the particular design constraints and innovative solutions implemented for the western portion of the site. The extreme below-ground congestion in that portion certainly pushed the limits of both design and construction capability in the U.K. Since 2004, the design team has been engaged in lengthy legal negotiations regarding land ownership and freehold of the portion of land occupied by the proposed London Underground Northern Line escalator, which sits within the developer’s site. The legal agreement with the Secretary of State for Transport required complete independence between the London Underground elements infrastructure (existing and proposed) and the proposed substructure of the developer’s over-site development.

Once the primary legal constraints and land ownership issues were resolved, the design team began early scheme design development leading to a series of solutions to form the foundations for the development. The initial design solutions considered bridging the Crossrail tunnel safeguarded corridor and cantilevering the building over the escalator box. Negotiations with the Crossrail Safeguarding Team led to a relaxation of the route safeguarding criteria that enforce a 6.0 metre lateral clearance zone (3.0 metre exclusion zone with a further 3.0 metre tunnel alignment adjustment zone). The team supported the negotiations using a state-of-the-art threedimensional numerical modelling simulation and buildability analysis capturing all key temporary and permanent works facets.

Unfortunately, regardless of the team’s achievements, the remaining constraints and resulting impacts did not meet the developer’s aspirations. The design team had to go back to

the drawing board. The key driver was developing a foundation solution for the western portion of the site and eliminating the large building cantilever over the escalator box. The team considered various foundation solutions to meet the legal agreement criteria between the developer and the Secretary of State for Transport. Restrictions in load transfer in the ground within the upper 30.0 m (98.4 ft) were prime considerations and design constraints.

The loading from the development had to be transferred to lower strata i.e., Lambeth Group

and Thanet Sands. The team considered constructing large hand- dug under-ream foundations and mined pad foundations beneath the escalator box.

Many other design options were discarded either due to construction programme drivers, spatial constraints and/or health and safety concerns. The design team focused on developing a unique large diameter piled solution in order to meet the various spatial, geometrical and functional constraints set-out. Numerous stakeholders and auth- orities needed to be

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Piling Industry Canada • June 2012 37

International fully engaged throughout the process to obtain the many necessary approvals.

Buro Happoldâ&#x20AC;&#x2122;s designers soon realised that a London Underground concession was required because foundation construction within the narrow strip of land between the escalator box and the Northern Line tunnels was well within London Undergroundâ&#x20AC;&#x2122;s 3.0 metre lateral exclusion zone for development. The design team needed to prepare and present a detailed submission presenting both design and construction facets, as well as a detailed risk assessment covering all temporary works elements. The resulting report had then to be presented to all key stakeholders.

In order to develop a highly engineered design solution, the numerical modelling simulation needed to be substantiated by high quality geotechnical parameters obtained from selfboring pressuremeter testing and instrumented triaxial testing on undisturbed samples, in addition to other more conventional testing techniques. Numerical modelling simulation was undertaken by means of three-dimensional finite element analyses, which were adopted for assessing the effects associated with pile construction on existing underground assets and for evaluating the performance of the over-site development substructure.

The design team proposed seven large diameter piles to support the entire western portion of the building. Each pile was unique and presented its own set of design and construction constraints depending on the degree of interaction with Crossrail and London Underground assets. From the beginning, it was clear that the designers would be pushing the envelope of pile construction capability in the U.K. A key aspect in delivering this scheme was the early involvement of selected specialist piling contractors to review buildability throughout the design development process. Bauer-Keller Joint Venture was awarded the piling contract under the umbrella of main contractor Taylor Woodrow-Bam Nuttall Joint Venture. Buro Happold and Bauer-Keller worked closely to understand and manage construction tolerances and plant capability to control and mitigate risks arising from the design development process.

A concession for piling at an unprecedented 1.1 metre clearance from the existing Northern Line tunnel was granted. Together with the agreed (also unprecedented) 1.0 metre clear38 PIC Magazine â&#x20AC;˘ June 2012

ance from the proposed Crossrail tunnel, the buildability of the scheme depended on high quality construction processes and first-class workmanship.

D-Shaped Pile Making the design a reality required a collaborative approach between all parties regardless of contractual arrangements and overarching land agreements. The highlight of the project was the first (and perhaps the last) D-shaped pile, which was installed along the western site boundary, sandwiched between the Northern Line tunnels and the escalator box. Although the over-site development building is not a high-rise structure, the loading on the pile is significant with compressive axial forces approaching 30MN (6,750 kip) and a bending moment in the order of 15MNm (3,375 kip) arising from the transfer building structure and the multi-faceted soil-structure interaction,respectively. A combination of factors led the Buro Happold design team to develop the D-shaped pile concept. The relatively high axial forces combined with sleeving of the upper 30.0 metres of the pile limited the available shaft capacity thus increasing the diametrical requirements. Having maximised the achievable pile length in terms of plant capability, the designers limited the pile length to 68.0 metres based on the Bauer BG40 rig.

This in turn led to a requirement for pile diameters exceeding 2.0 metres, which could not be accommodated within the available space between the escalator and the Northern Line tunnels.

By designing the upper 30.0 metre portion of the pile as a D-shape, instead of the usual circular cross-sectional geometry, the team could accommodate the load carrying requirements by means of a traditional circular pile below the level of the Northern Line tunnels.

The flat side of the D-shaped pile formed the internal face of the escalator box whilst providing a fully-independent sleeved foundation solution for the over- site development within the site boundary line.

Constructing the seven piles sup- porting the western portion of the building, in particular the D-shaped pile, required careful planning. In addition, the piles necessitated a Justin-Time supply chain arrangement due to site constraints from an operational and materials storage perspective. The outline construction

sequence included installing a 2.5 metre diameter temporary casing into the London Clay.

This casing provided a groundwater cut-off and support to upper granular deposits, thus enabling open boring within the London Clay stratum. As the pile bore approached the live Northern Line tunnels, we used an oscillator to install the 2.0 metre diameter permanent outer steel casing. The oscillator possessed 4,000 kNm (2,950 kip.ft) torque and was the largest and most powerful piece of equipment of its type that can be used in conjunction with the BG40 rig.

The outer permanent steel casing was oscillated past the Northern Line tunnels in 1.0 metre increments i.e., in turn, by oscillating the casing by 1.0 metres followed by advancing the pile bore by 1.0 metres.

The contractors drilled past the tunnel during engineering hours as night-shift work. The remainder of the boring operation (below the 30 metres) deep permanent outer casing) was undertaken using support fluid to control pile bore stability within the lower granular strata and groundwater within the lower aquifer. In the instance of the D-shaped pile, the construction sequence called for installing a 30.0 metre long D-shaped permanent inner casing together with the lower circular reinforcement cage and the upper D-shaped reinforcement cage and instrumentation with a combined lift approaching 100 tonnes. Once in place, the concrete was tremied in and support fluid was displaced from the bore. Next, after excavation of the escalator box, the outer steel casing was cut back, exposing the flat side of the Dshaped inner casing.

Design as Risk Mitigation Design is simply a risk mitigation exercise.

If a highly-engineered solution is substantiated by appropriate ground investigation, means of analysis and real-time monitoring, it is evident that we are able to push the boundaries to maximise the value we provide as designers and engineers. Innovation in design and construction are inherently connected and interdependent. The success of this scheme was driven by the collaborative effort of all parties involved, from the various client bodies, stakeholders and authorities to the designers and contractors. n

International

Big Links World’s largest piling links Hong Kong, Macau and Zhuhai

By Michael Schwartz

Two hundred people gathered last December

most important industrial locations was to

est concrete piles ever seen at that time into a

to witness the driving into place of the last

be realized; within this project piling was to

project in the Yangtse. These piles measured

of 120 piles vital to the Hong Kong-Zhuhai-

be crucial. APE (America Pile-driving Equip-

40 feet in diameter and weighed 550 tons.

Macau bridge and tunnel complex, itself a

ment of Washington State, U.S.) was appoint-

For the new bridge APE was initially asked

dream going back nearly 30 years. The com-

ed to carry out the piling; Shanghai-based

whether it could – in theory at least - connect

plex measures 50 kilometres in length, and a

ZPMC fabricated the 120 piles.

eight of the largest hammers ever built in the

west-east cross-section reveals the challenges

Design organizations from the Chinese

U.S. into one massive single entity.

the project’s pioneers face: a link road from

government supported the concept of 120

All eight hammers were to be linked hy-

Macau to an artificial island east of Macau,

large diameter steel caissons for the project;

draulically, one of the factors that gave rise

three-lane dual-carriageway bridging, 6.7 ki-

they had calculated that if piling of this na-

to the machine’s name, the OctaKong. In

lometres of undersea tunneling in the middle

ture was feasible, two years could be shaved

fact, each hammer is named APE SuperKong;

stretch, a second artificial island, more three-

off the original plan which envisaged sheet

when all eight came together APE nearly

lane bridging, and finally a 12 kilometre link

piles. The large diameter design was selected

named the machine the OctaSuper-Kong,

road onto Hong Kong territory.

by China Construction Bureau in mid-2010,

which in David White’s opinion would have

Each island will occupy 12 hectares. The

with APE winning the contract to produce the

been more accurate. The bottom line for the

longest bridge section will be 22.8 kilometres

pile-driving machinery in November 2010.

OctaKong in terms of power statistics was

long and will include three cable-stayed spans

in excess of 4,000 U.S. tons of force from a

between 280 metres and 460 metres, with the

The project in its perspective

9,600 hp power unit; eight APE Model 600

longest bridge section 22.8 kilometres long

APE’s task was clear: driving piles up to 22

hydraulic vibratory hammers would be linked

and including three cable-stayed spans be-

metres in diameter, 25 milimetres thick, 54

together around the top of the pile to generate

tween 280 metres and 460 metres. A seven-

metres tall and weighing 665 U.S. tons (pil-

vibration into the pile.

year construction period started in December

ing plus internal bracing) into N30-50 sand

2009 will conclude in 2016.

to depths of 36 metres. Neither the pile itself nor the pile-driving required had ever been

Soil resistance a real challenge

Why were these piles needed?

attempted.

To say there were unique challenges for

Manmade islands were always going to be

APE had already connected four of its

any party involved with the project is some-

vital if the dream of linking three of China’s

model 400 hammers in order to drive the larg-

what of an under-statement. As if the width

40 PIC Magazine • June 2012

International of the piles was not challenging enough, the soil conditions which prevail on the bed of the Pearl River delta are themselves highly varied, sometimes within just a few metres.

For example, while soil layers may not be completely flat, that does not automatically pose a problem. Where this project differed was that one side of the pile might already have cut through three metres of a soil layer before the other side of the pile even reached the same soil layer.

At certain times, therefore, one side of the pile might be introduced into N47+ soil while the left side saw only N15. Soil at the Macauside island measured N27, meaning fairly smooth driving; a straight alignment of the piles was the challenge here. In turn, difficulties in positioning the first pile meant it took around ten hours to drive it.

Eventually, improved positioning techniques meant that a pile could be driven within two hours (vibration times were always more consistent, running between ten and thirty minutes per pile).

At the Hong Kong island the more acute differences in soil consistency were encountered. APE project manager David White summarises, “Essentially…we were driving through two different soil conditions at once…When using vibratory hammers the frequency of the hammer can be changed on the fly to better match the soil condition.

“Sometimes a low frequency is more efficient when driving in hard soil and high frequency is more efficient in soft soils. However, in our case we were not able to find a frequency that both satisfied the two soil conditions that were being penetrated at the same time.

Therefore the driving time for the first pile took three days…”

APE devoted many hours of meetings to work out how to overcome the soil differences. Their techniques must remain confidential but the project headache now passed to ZPMC, who had to keep up with demand for two piles per day!

Pressures on APE APE encountered more pressures on this project than any contractor could normally expect from any civil engineering project.

Even after accepting that the piling was possible in theory, there was the extremely difficult Piling Industry Canada • June 2012 41

International task of keeping all eight hammers in perfect synchronization.

At its bluntest, hydraulic vibratory hammers vibrate spinning counter-weights. Each of these causes each hammer to shake up and down; however, if even one hammer vibrated out of phase from the others it would generate so much heat it would actually melt steel in less than 15 seconds!

Pressure on the design and engineering expertise of the APE’s team was incalculable.

Vibrating a 22 metre diameter pile meant that the hammers were also 22 metres apart: if any one of the eight hammers was to fall out of synchronisation by just 1/300th of a second APE’s calculation was that the pile would tear itself in half and cause the most serious harm to anybody standing next to that pile.

Pile rigidity, or lack thereof, posed yet another problem. Diaphragming will occur with larger piles, meaning power loss at certain frequencies due to flexing. APE employed 24 equally spaced clamps around the top of each pile to hold it steady. Once these clamps were closed, extra rigidity was imparted into the hammer.

Then there were the pressures arising from the timetable and the need for mechanical reliability. Tensions ran high for seven months due to the extremely tight timeline for the piling. It was also all too clear to APE that breakage or failure of the OctaKong equipment would mean the piling would not be completed on time; APE did not even have the back-up of a replacement for a unique piece of equipment.

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APE’s solution Because of the severe pressures mentioned, APE had to adopt practices which would mean punctual and safe completion of the project. Every single hammer was inspected before and after each of the 120 piling operations. Next, APE time-managed the hammers, ensuring that precious time was not wasted – and the timetable put in jeopardy.

APE is now contributing the knowledge it acquired from the Hong Kong-Macau project towards improving piling technology. APE is pleased to acknowledge the opportunity it enjoyed while working with China’s Number 1 Marine Construction Bureau; future working methods will benefit from those required through the sheer size of the project.

In fact, APE is thoroughly confident that techniques it has applied here are a huge step for the pile-driving industry, whether in the form of even larger bridges and land reclamation projects, and could revolutionize the wind power industry, with anything between three to six wind-farm piles per day becoming feasible.

David White’s pride – not to say relief – in achieving the piling on time is almost tangible, “It was a surreal feeling to watch the last pile go into the ground after nearly two years of research and planning…APE China felt the heat to make sure the project kept going smoothly. I’m glad to report that the OctaKong hammer never had even one day of downtime, something our APE team should be very proud of.” n

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Piling Industry Canada • June 2012 43

International

All Around The World A profile on two of Liebherr’s international projects Liebherr piling and drilling rig LRB 155 in CMC application working at Jakarta International Airport, Indonesia In Indonesia the company Menard is currently working for main contractor PT Adhi Karya at Soekarno Hatta International Airport in Jakarta. The task is to improve the ground condition of a 65000 m² area that will become an extension of the Apron Pier at Terminal 3. The aim is to reach ground bearing capacity of CBR six per cent to be able to carry the load of aircrafts including Jumbos during parking and taxing for many years to come. To achieve this, Menard chose the CMC method (Controlled Modulus Column) and uses a Liebherr LRB 155 hydraulic multi-purpose piling and drilling rig from Liebherr.

During the five month period Menard will complete 14,112 piles with a diameter of 320 milimetres and depths between 2.2 metres and 12.5 metres. They are working in 10 hour shifts and are able to complete approximately 200 piles per day on average. “Due to the better than expected performance of the Liebherr LRB 155, we should be able to complete the project one month ahead of time,” says Loo Shih Chuan, project manager of Menard.

One of the reasons PT Adhy Karya choose Menard to complete this prestigious task was the fact that Menard is able to document and proof the quality of each single pile with the Liebherr PDE® process data recording system, which is installed in the LRB 155.

On a colour touchscreen in the operator’s cab current process data (e.g. location, depth, rotary torque pressure or penetration/pulling speed) are displayed in real time so the operator is constantly informed about the working process and is able to control it accordingly. All data are recorded on a memory card in the operator’s cab.

With the aid of the process data reporting software SCULI PDR the data generated by the PDE® system can be managed on a PC and evaluated extensively after the working process. A vital element of SCULI PDR is the report generator, which allows for the generation of individual jobsite protocols. The proto44 PIC Magazine • June 2012

cols can be freely configured, displayed in a variety of languages and either printed out directly or stored as PDF file.

A robust leader concept offering maximum versatility is a prerequisite for precise work. Furthermore, the innovative rope crowd system featuring extremely high pull and push forces contributes to the excellent performance of the Liebherr piling and drilling rigs. The powerful 450 kW Liebherr V8 diesel engine of the LRB 155 allows operation of equipment solely via the rig’s on-board hydraulics. Thus, no additional power packs are needed for the equipment, which leads to a significant reduction of the total costs for the contractor. Apart from the enormous savings in fuel consumption this also entails a reduction in maintenance costs and noise emissions.

After having completed the West Wing area, Menard is optimistic that due to their good overall performance, which is greatly due to the Liebherr LRB 155, they will have good chances to get the follow up order to perform the planned phase 2 and phase 3 of the Terminal 3 Apron Pier Extension. Both additional phases will be about the same size as phase 1 and are scheduled to start next year.

Liebherr piling and drilling rig LRB 255 installing a vibrated beam slurry wall in Styria The Austrian energy and environmental services company evn naturkraft is building a hydro-electric power plant on the River Muerz near Schaldorf, St. Marein in Styria, for the environmentally friendly production of electricity. In March and April 2011 the construction company G. Hinteregger & Soehne Baugesellschaft m.b.H. installed a vibrated beam slurry wall to seal off the foundation pit.

For this job the Hinteregger company relied on the rental fleet of Liebherr-Werk Nenzing GmbH, which provided a Liebherr piling and drilling rig, type LRB 255, with a 27 metres leader for the slurry wall work.

Due to the requirement of vibrating, a 22 metre long 800-IPB steel beam into dense (and in some cases very dense) gravel and sand, the process engineers of Liebherr-Werk Nenzing GmbH recommended the use of a normal frequency vibrator. Hinteregger trusted this recommendation, and the LRB 255 basic machine was

International fitted with a PVE 105M vibrator with gear oil cooling. The combination of the LRB 255 with 605 kW engine power and the PVE 105M with 105 kgm static moment and a maximum operating frequency of approximately 23 Hz were particularly convincing during the entire project. Thus, approximately 4,700 square-metres of vibrated beam slurry wall were produced in 13 workdays. The depth of each panel was between 17 and 20 metres, the production of one panel requiring an average of 15 to 20 minutes. The peak daily production was approximately 460 square-metres. During the vibration work, a total of about 1640 m³ of cement slurry was pumped into the ground to create the required impermeable foundation pit enclosure.

The range of Liebherr piling and drilling machines of the LRB series currently includes three sizes with operating weights ranging from approximately 45 to 85 tonnes and leader lengths between 15.5 and 30 metres. Thanks to the high engine power of 450 to 670 kW the hydraulic supply of working tools requires no additional hydraulic power packs while diesel consumption remains low. The Liebherr piling and drilling rigs are equipped with a rope crowd system offering impressive pull and push forces of up to 450 kN. Combined with the versatile, yet robust leader kinematics utmost working precision is achieved.

Basic machine and working tool are controlled entirely from the comfortable operator’s cab thanks to the latest CAN-Bus technology.

For the assistance of the operator and for quality control of the work performed, the machines of the LRB series can be equipped with the Liebherr PDE® process data recording system. The PDE® system serves to electronically record and visualize the process data. Operation and display is carried out via the PDE® colour touchscreen in the operator’s cab. The PDE records process data from the Litronic control system (e.g. pressure or rope length measurement) as well as data from external sensors (e.g. frequency transmitter or slurry flow meter). Depending on the working process the data are interlinked and stored on a CompactFlash(CF) memory card together with individually configurable details (such as jobsite name, pile number, date, time etc.). Using the optional printer protocols can be printed in the operator’s cab directly after completion of the working process.

PDR, the process data reporting software, enables comprehensive data evaluation and report generation on a PC. The recordings generated by the PDE® system can be imported, either directly from the CompactFlash memory card or via the Liebherr telematics system LiDAT, and managed in PDR. Various filter functions facilitate the sorting of imported recordings. The data in each record is displayed tabularly. Combining several recordings provides results, for example, regarding the total slurry consumption or the daily production.

Furthermore, a diagram editor is available for quick analysis. A vital element of the Liebherr process data reporting software PDR is the report generator, which allows for the automated generation of jobsite reports. These can be generated in over 20 different languages and either sent to a printer or stored as PDF files.

The report configurator allows the reports to be individually arranged. The process data recorded by the PDE® system can be selected and displayed with reports in the form of time-dependent or depthdependent diagrams. Axes’ lettering, line thicknesses and colours, scalings or the printing of company logos are individually configurable as required. n Piling Industry Canada • June 2012 45

Index to Advertisers American Piledriving Equipment Inc.

31

Northstar Inc.

Arntzen Corporation

35

Pile Dynamics, Inc.

35

Bauer-Pileco Inc.

13

Pile Drivers Local Union 2404

43

Bay Shore Systems, Inc.

11

Pinnacle Drilling Products LP

42

Platinum Grover International Inc.

21

Roll Form Group

17

Bermingham Foundation Solutions

9

Canadian Pile Driving Equipment Inc.

37

D.A. McIntyre Construction Ltd.

26

Dominion Pipe & Piling

IFC

Eastrock Inc.

15

ECA Canada

3

Geokon, Incorporated

19

Hammer & Steel, Inc.

OBC

RST Instruments Ltd.

8

Skyline Steel

7

Soilmec North America

27 23

Waterloo Barrier Inc.

Irving Equipment

29

Watson Drill Rigs

Mississippi Valley Equipment Company

30

6

Tadano Mantis Corporation

25

OFC & 4

39

Spiralco Inc.

Interpipe Inc.

Liebherr Werk Nenzing GMBH

5

IBC

Weatherall Dock and Dredge Inc.

24

Westco Drilling & Piles Ltd.

18

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