Cvijanovic PDF

State-of-the-art sheet piling foundation
solutions and their applications
Bernard Cvijanovic
Senior Sales Manager, ArcelorMittal Commercial RPS
Buenos Aires, 24th August 2011
Buenos Aires, 24th August 2011 Foundations Conference Argentina 2011

Agenda
• Introduction to ArcelorMittal’s state-of-the-art range of foundation solutions

• Solutions for transport & urban infrastructure projects
– Case study ‘Unterinntalbahn’ (Brenner) railway line, Austria
• Straight web sheet pile solutions
– Case study Solis hydroelectric dam, Switzerland
• Recent innovation – durability example
• ArcelorMittal – your worldwide one-stop provider of foundation solutions
1
A bit of history…
• First rolled steel sheet pile in USA: Lackawana type, 1908.

• Since 1911, ARBED / ARCELOR / ArcelorMittal have improved sheet pile sections
2
Types of steel sheet piles – 1
U - section
Z - section
Combined wall
3
Types of steel sheet piles – 2
Max. Wx (cm3/m) approximately:

Section modulus Wx per type of
• U-type: 3 200 sheet pile solution
• Z-type: 5 000
• HZM/AZ: 46 500 50 000
46500 45000
45 000
• Pipe/AZ: 45 000
40 000
35 000
Applications:
Wx (cm3/m)
30 000
• temporary, small excavations / 25 000
retaining structures: 20 000
W x < 2 500 15 000
• marine structures (<12.0m dredge 10 000
5015
level) / deep excavations: 5 000
3200
W x < 5 000 4800 4000
0
• large quay walls / deep cofferdams: U-type Z-type HZM/AZ Pipe/AZ
Wx > 5 000
4
Hot rolled Z and U type steel sheet piles (2011)
AZ 13 AZ 18 AZ 26 AZ 48
Z type
AZ 13-770 AZ 18-700 AZ 26-700 AZ 38-700N
PU 12 PU 18 PU 22 PU 28 PU 32
GU 7N GU 13-500 GU 16-400
U type
AU 16 AU 20 AU 25
5
Old range of HZ / AZ (since 1990’s)
23
17
1050
462
HZ575 HZ775 HZ975 HZ1050
• Combined wall system with 4 sections, 4 thicknesses (A, B, C, D):

• Elastic section modulus W el,y 2 870 – 32 045 (cm3/m)
• Moment of inertia Iy-y up to 1 731 300 (cm4/m)
6
Steel grades for hot rolled steel sheet piles
EN 10248 ASTM JIS

fyk fyk fyk fyk
[MPa] [ksi] [MPa] [MPa]
S 240 GP 240
S 270 GP 270 A 328 39 270 SY 295 295
S 320 GP 320
S 355 GP 355 A 572 Gr. 50 50 345
S 390 GP 390 A 572 Gr. 55 55 380 SY 390 390
S 430 GP 430 A 572 Gr. 60 60 415
S 460 AP* 460 A 572 Gr. 65 65 450
• Addition of copper 0.35%, 0.50%

• ASTM A 690: high strength low alloy steel for use in
marine environments (Gr. 50 and higher available)
7
Agenda

8
CASE STUDY
Unterinntalbahn (Brenner) project – Austria
• Carried out by
9
Challenges
• All retaining walls initially designed in concrete – sheet pile combined walls not
previously used in Austria as temporary structure
• Proximity to existing (running) railway line and roads, and to buildings
• Proximity to river Inn and risk of flooding
• Existing groundwater level
• Multiple crossing over/under river, roads and existing railway
• Multiple construction methods
– Conventional tunneling (including under compressed air)
– Cut-and-cover method with underwater concreting
– Shield tunneling method
• Many different cross sections along the 40km track
10
New range of HZ-M
Nb of h t s w
sections (mm) (mm) (mm) (mm)
HZ 880 M A, B, C 831 19 - 23 13 - 15 458 - 460

HZ 1080 M A, B, C, D 1075 20 - 30 16 - 19 454 - 457
HZ 1180 M A, B, C, D 1075 - 1087 31 - 37 20 - 22 458 - 460
w/4
w tmax tmax
r t
h h1 y y h y y
h h1 y y s s
s
HZ 880 M HZ 1080 M HZ 1180 M
t = 19, 21, 23 mm t = 20, 23, 26, 30 mm t = 31, 33, 35, 37 mm
11
Comparison HZ-M / HZ
Standard AZ infill sheets:

AZ13, AZ13-770, AZ18, AZ18-700,
AZ26, AZ26-700
Iy Wel,y * G100%
(cm 4/m) (cm 3/m) (kg/m2)
HZ 575 A-12/AZ13 96 470 2 870 178

HZ 1050-C23 1 731 300 32 045 705
HZ 880M A-12/AZ 13-
+ 45%
215 290 4 815 200
770
2 579 400 46 500 992
HZ 1180M D-C23
Combination C23
Combination 12
12
New HZ-M production facility
Concept: milling instead of rolling

Two separate milling tools are shaping the groove into the HZ-M flange to enable the
threading of connectors for AZ-infill elements.
13
Performance of new HZ-M range
HZ-M
HZ…. 12 & 24
Infill sheet pile: AZ18-700
13 265 18 895
14
Driving tests HZ king piles
• First temporary use of HZ-AZ

combined wall system in Austria
15
Driving tests AZ sheet piles
16
Driving tests – water jetting
tubes
15 ÷ 25 bar Water
Pump Tank
17
Declutching detection: DIXERAN
If necessary to verify the integrity

of the wall, i.e.:
Detail A
• hard driving / obstacles
• cut-off walls (environmental jobs)
Protection cap ‘Dixeran’: detector to verify the

Control box shearing of a pin
Detail A
18
Cut & cover building phases – 1
19
Driving of sheet piles
20
Example of driving plan
HZ-AZ combined walls and PU anchor walls
21
HZ-AZ combined walls and PU anchor walls
22
Introduction of sealant – use of driving template
23
PU anchor wall
24
Dredging works
25
26
Underwater works supervised by divers
27
Anchoring & concreting
28
Dewatering of trenches
29
30
Finishing concreting works after dewatering
31
Tunnel construction / introduction of tunneling
machine in finished dry trench
32
Removal of sheet piles for re-use or sale
33
Temporary sheet pile retaining wall for
safety shaft
34
Proximity to roads and existing railway
35
Congonhas Airport, Sao Paulo, Project Location

Pile driving

Concrete capping beam

Installation of prefabricated elements as cover

Excavation

Concrete base slab

Tunnel entrance, excavation

Excavation independent from other work

Concrete Base slab

Finished construction

Other major recent transport infrastructure projects
Widening of M1 & M25 motorways, UK
h
August 2011
Vienna Metro, Austria
High Speed Line, Netherlands

46
Examples of sheet piles in permanent use for
transport / urban infrastructure
Flood defences
Bridge abutments
Underground car parks

Piling and Deep Foundations Africa 2011 47
Waste Disposals

Waste Water Treatment
Waste Water Treatment Plant, Germany

• Sheet Piles for vertical support during excavation
• and as permanent perimeter wall of the structure
• HP-Piles prevent hydraulic uplift of the concrete slab
Agenda

50
Straight web steel sheet piles AS 500
Width = 500 mm (nominal) Thickness Interlock

fyk
min. yield
web strength
strength
AS 500
[mm] [kN/m] [MPa]
9.5 3000 355
11.0 3500 355
12.0 5000 355
12.5 5500 355
12.7 5500 355
• gravity structure
300 mm ≤ L ≤ 500 mm
• deep wharfs / quays / breakwaters / cofferdams
testing: EN10248-1
• structures founded on bedrock
• no anchors
51
Types of cells
Circular cells
junction pile
Diaphragm cells
52
CASE STUDY
Solis hydroelectric dam, Switzerland
53
Looking for a solution – 1
54
Looking for a solution – 2
55
Original design – complex double-walled sheet pile
cofferdam with 6 levels of struts
56
After optimization…
57
Section along cofferdam
Max. sheet pile Gravel backfill

length 30.5m
Lake bed
Silty lake sediments
φ ∼ 20-24°
γ ~ 19-21 kN/m3
Rock line Splicing to add 6m of

length + grouting
• 528 sheet piles (AS500-9.5 and AS500-12) with a total tonnage of 859 kt were delivered.
58
A logistical challenge
Spreader beam
with attachment
for handling of
long piles
59
Putting into place the circular template
60
Installation
junction pile
61
After excavation and drainage
62
Next step – reuse of sheet piles and conversion
from temporary to permanent cofferdam!
63
Dique de Carena, Puerto General Belgrano, Bahia
Blanca

Blanca

Blanca

Blanca

Blanca

Blanca

Seo-Hae Grand Bridge, South Korea
70
Tug-boat quay in Paraíso, Panama Canal
AS 500-12.0
20 circular cells
φ = 15.0 m, L = 18.5 – 20.0 m
≈ 3000 t
71
Circular Cell Structure
E-METHANEX Berth, Damietta, Egypt
72
Diaphragm Cell Structure
Essar Quay wall, Hazira, India
73
Agenda

74
Durability of steel structures
• corrosion in undisturbed natural soils is negligible (exception peat, …)

• in common fresh water, corrosion is low
• in sea water, corrosion has to be considered (splash zone, low water)
• reference for loss of steel thickness: Table 4.1 & 4.2, EN 1993-5 (2007)
design life (years) 5 25 50 75 100

undisturbed natural
0.00 0.30 0.60 0.90 1.20
soils (sand, clay, …)
common fresh water:
0.15 0.55 0.90 1.15 1.40
waterline
sea water: permanent
0.25 0.90 1.75 2.60 3.50
immersion & intertidal
sea water: splash &
0.55 1.90 3.75 5.60 7.50
low water zone
75
Introducing AM LoCor™
76 76
Agenda

77
ArcelorMittal Sheet Piling ⇒ Foundation Solutions
• extensive engineering pool & technical

assistance team for external interventions
• provide regular in-house training for internal and

external technical sales force
• elaborate adequate design software & update

technical documentation (PHB,…)
• provide educational training programs for

engineers at universities, consultants and
contractors
• leading participation for EC standards, NASSPA,

Chinese Standard Institute, Brazilian Standard
Institute for the construction industry
78

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State-of-the-art sheet piling foundation

solutions and their applications

Buenos Aires, 24th August 2011 Foundations Conference Argentina 2011

• Introduction to ArcelorMittal’s state-of-the-art range of foundation solutions

• First rolled steel sheet pile in USA: Lackawana type, 1908.

Max. Wx (cm3/m) approximately:

HZ575 HZ775 HZ975 HZ1050

• Combined wall system with 4 sections, 4 thicknesses (A, B, C, D):

EN 10248 ASTM JIS

• Addition of copper 0.35%, 0.50%

• Introduction to ArcelorMittal’s state-of-the-art range of foundation solutions

HZ 880 M A, B, C 831 19 - 23 13 - 15 458 - 460

HZ 880 M HZ 1080 M HZ 1180 M

t = 19, 21, 23 mm t = 20, 23, 26, 30 mm t = 31, 33, 35, 37 mm

Standard AZ infill sheets:

HZ 575 A-12/AZ13 96 470 2 870 178

Concept: milling instead of rolling

• First temporary use of HZ-AZ

If necessary to verify the integrity

Protection cap ‘Dixeran’: detector to verify the

Buenos Aires, 24th August 2011 Foundations Conference Argentina 2011

Buenos Aires, 24th August 2011 Foundations Conference Argentina 2011

Buenos Aires, 24th August 2011 Foundations Conference Argentina 2011

Buenos Aires, 24th August 2011 Foundations Conference Argentina 2011

Buenos Aires, 24th August 2011 Foundations Conference Argentina 2011

Buenos Aires, 24th August 2011 Foundations Conference Argentina 2011

Buenos Aires, 24th August 2011 Foundations Conference Argentina 2011

Buenos Aires, 24th August 2011 Foundations Conference Argentina 2011

Buenos Aires, 24th August 2011 Foundations Conference Argentina 2011

Buenos Aires, 24th August 2011 Foundations Conference Argentina 2011

Widening of M1 & M25 motorways, UK

Vienna Metro, Austria

High Speed Line, Netherlands

Underground car parks

Buenos Aires, 24th August 2011 Foundations Conference Argentina 2011

Waste Water Treatment Plant, Germany

• Introduction to ArcelorMittal’s state-of-the-art range of foundation solutions

Width = 500 mm (nominal) Thickness Interlock

12.0 5000 355

12.5 5500 355

12.7 5500 355

Max. sheet pile Gravel backfill

Rock line Splicing to add 6m of

Buenos Aires, 24th August 2011 Foundations Conference Argentina 2011

Buenos Aires, 24th August 2011 Foundations Conference Argentina 2011

Buenos Aires, 24th August 2011 Foundations Conference Argentina 2011

Buenos Aires, 24th August 2011 Foundations Conference Argentina 2011

Buenos Aires, 24th August 2011 Foundations Conference Argentina 2011

Buenos Aires, 24th August 2011 Foundations Conference Argentina 2011

• Introduction to ArcelorMittal’s state-of-the-art range of foundation solutions

• corrosion in undisturbed natural soils is negligible (exception peat, …)

design life (years) 5 25 50 75 100

• Introduction to ArcelorMittal’s state-of-the-art range of foundation solutions

• extensive engineering pool & technical

• provide regular in-house training for internal and

• elaborate adequate design software & update

• provide educational training programs for

• leading participation for EC standards, NASSPA,

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