building the foundations of australia
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast. Presentation EXTREME COMPRESSION AND TENSION LOADS FOR THE SOUL TOWER, A 77 STOREY APARTMENT BUILDING ON THE GOLD COAST 12th May 2010, 9.15 pm IQPC Piling & Deep Foundations Conference Melbourne - PowerPoint PPT PresentationTRANSCRIPT
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Building the Foundations of Australia www.pilingcontractors.com.au
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Presentation
EXTREME COMPRESSION AND TENSION LOADS
FOR THE SOUL TOWER, A 77 STOREY
APARTMENT BUILDING ON THE GOLD COAST
12th May 2010, 9.15 pmIQPC Piling & Deep Foundations Conference Melbourne
Hotel Bayview Eden, MelbourneSpeaker: Martin Larisch (Piling Contractors)
Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Site location of Soul in Surfers Paradise, QLD
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Finished appearance in Surfers Paradise, QLD
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Site location of the project in Surfers Paradise, QLD
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77 storey apartment building with a retail area surrounding the main
tower
Third highest residential building in Australia (277m)
Beach front location in the heart of Surfers Paradise
Demolition works started in December 2007, proposed completion
of the
project mid of 2011
Main Contractor of the D&C project is Grocon Constructors (QLD)
Pty Ltd
Piling works awarded as D&C package to Piling Contractors Pty Ltd
in
December 2007
Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Introduction: About the Soul Project
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Developer employed McConnell Consulting in 2005 to carry out a soil
investigation comprising 4 boreholes with SPTs and undisturbed sampling in
soils and NMLC triple tube coring in rock
Point load index tests on rock samples
Classification tests on soil samples
Noted that the concept was for a very tall structure with unusually deep
basements
Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Introduction: Early Site Investigation
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Grocon employed Golder Associates in 2007 to review Site Investigation and
make recommendations:
Data from this site and two adjacent sites considered in new report
Suggestion of ranges of UCS and Modulus
Use of ROCKET to determine ranges of shaft friction
Base resistance greater than available concrete strength
Recommendation of additional drilling
Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Introduction: Site Investigation used for pile design
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Introduction: Piling works
Pile installation was carried out in four stages from January – Sept. 2008
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Pile layout plan - Pile installation
Stage ICFA piles 01/2008
Stage IItower piles03-08/2008
Stage IIICFA piles
05-07/2008
Stage IVCFA piles09/2008
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Tower piles
Pile layout plan - Location of tower piles
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Bored piles for the main tower
44 large diameter bored piles (installed under bentonite) for the main
tower
pile cut off levels 9m & 14m below working platform
plunged steel columns required for 21 piles
pile Ø 1500mm, 1800mm and 2200mm
drilling depths up to 45m
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
1800mm
1500mm
Pile Layout Plan - Pile diameters tower piles
2200mm
column
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Site Geology - Site location of Soul in Surfers Paradise, QLD
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Site Geology - Assumed soil profile
Typical site conditions detailed in the chart below:
ELEVATION BRIEF DESCRIPTION
+5m to -1.5m Fill (loose silty sand and clayey sand)
-1.5m to -21m Sand (dense to very dense with some sandy clay lenses)
-21m to -33m Sandy clay and clayey sand (ranging from stiff to medium dense)
-33m to -36m Greenstone / Argillite (very weak)
-36m to -48m Argillite (Neranleigh - Fernvale Group)
-48m to -60m Argillite (Neranleigh - Fernvale Group) but RQD > 70% (assumed)
below -60m Massive Argillite (assumed)
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Site Geology - Further Site Investigation by Grocon / Golder
One additional borehole drilled to 42m depth (-44.5m AHD)
Results confirmed previous investigation
Pile bases had to be very clean to mobilise end bearing
100% requiring a comprehensive cleaning system and SID
Some base debris, requiring sweep airlift and purpose built cleaning
buckets; bentonite with <2% sand content
Shaft friction only, requiring conditioning of drilling fluid and cleaning
bucket
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Site Geology - Assumed soil profile
Golders0
10
20
30
40
50
60
70
BasementSandGreenstoneArgillite
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Site Geology - Summary point load tests
0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0-1.0
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
S-1S-1S-2S-3S-3S-4S-4S1 AxialS1 DiametralS2 DiametralBH1
Point Load Index (MPa)
Dept
h be
low
top
of A
rgill
ite (m
)
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Site Geology - Design parameters
Point load tests from two independent soil investigation reports
indicate
high strength to very high strength Argillite in the target founding zone
for pile toe levels
Piles to be designed with rock sockets of at least one pile diameter
into
high strength Argillite or better (UCS between 20-30 MPa)
Piles with high tension loads to be designed and constructed with
longer rock sockets of 3.5m
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Site Geology - The following parameters were recommended:
Depth Material UCS (MPa) E (GPa)
9 to 38.7m Very dense sand - 0.05 to 0.1
38.7 to 41.5m Greenstone 5 to 10 0.5 to 1.0
> 41.5m Argillite 20 to 30 4 to 6
Ultimate shaft resistance (kPa)
Depth Material Minimum Maximum
9 to 38.7m Very dense sand 100 150
38.7 to 41.5m Greenstone 500 750
> 41.5m Argillite 1200 2500
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Site Geology - Geotechnical design by Piling Contractors
Piling Contractors appointed PSM to carry out geotechnical design review
Examined soil profile
Carried out FE modelling
Minor modifications to socket length suggested and accepted by MJ Civil
Looking at settlement and differential settlement, and at tension capacities
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43
02468
1012141618
DL + 40% LL settlement Serviceability settlement
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Building loads for the Soul tower
Vertical compression load of building (MN)
Vertical tension load (MN)
Lateral load (MN)
DL + 40% LL Serviceability Ultimate
1060 1573 2170
Ultimate
213
Ultimate
65.5
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Pile loads (ULS) for the tower piles
1500mm piles 18-32MN in compression, average 24-
26MN
0-3MN in tension
1800mm piles 30-51MN in compression, average 38-
44MN
0-5MN in tension
2200mm piles 37-90MN in compression, average 50-
60MN
0-18.6MN in
tension
Pile P11 (Ø2200mm) with ULS load of 90MN in compression
Pile P14 (Ø2200mm) with ULS load of 18.6MN in tension
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Pile loads (ULS) for the tower piles
10000 20000 30000 40000 50000 60000 70000 80000 90000 1000000
5000
10000
15000
20000
25000
CP pilesP piles
Ultimate compressive load (kN)
Ultim
ate
tens
ile lo
ad (k
N)
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Major technical challenges of the project
Tower piles with very high compression and tension loads - ULS pile
loads
up to 90MN (compression) and 18.6MN (tension) per pile
Requirements for elimination of structural concrete cracking under
tension loads→ Minimum characteristic concrete principal tensile strength (f’ct)
shall be 0.4√ fc’
Pile installation within tolerances is imperative
Installation of plunged columns in tension piles
Pile cut off levels located 9m and 14m below working platform
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Options for compression loads
Driven piles
Not suitable for the intensity of loading
Raft foundation (stiffened raft/slab or piled raft)
Considered by McConnell Consulting for basement/podium
foundations
CFA piles
Used for podium foundations
Bored piles socketed into rock
Used for tower foundations
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Options for tensile loads
Driven piles
Not suitable for the magnitude of loading, joints etc
Raft foundation (stiffened raft/slab or piled raft)
Not suitable for uplift in excess of dead weight
CFA piles
Problems with full length reinforcement
Bored piles socketed into rock
Used for tower foundations
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Pile Design - Piling works as D&C contract
Piling Contractors first tender proposal
Pile diameter Quantity
1200mm 2
1500mm 15
1800mm 13
2200mm 10
3000mm 3
Pile diameter Quantity
1500mm 7
1800mm 18
2200mm 19
Revised and optimized proposal
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Why was the reduction of 3000mm to 2200mm piles important?
3000mm piles with 86% more volume (influences drilling rates,
cleaning
of drilling fluid, storage capacities, steel and concrete quantities)
3000mm piles with 36% deeper rock sockets
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
How can the tension capacity of bored piles be improved?
→ Use of high strength concrete (fc’ > 85MPa) for the pile shaft
providing additional tensile capacity
Workability criteria
several 1500mm and 1800mm piles were installed and poured
successfully with the 65MPa mix (no blockages)
slump of 260mm, spread 600mm
workability for 8-10 hours to ensure contingency
delivery and supply of concrete without delays
no concrete bleeding or segregation observed
concrete strength achieved
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Use of high strength concrete
Plunged column installation
site trial with a test column in a 1500mm pile to verify minimum
plunged depth of 10m into concrete
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Use of high strength concrete
Plunged column installation
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Concrete Design Requirements
Design criteria
according to minimum characteristic concrete principal tensile
strength (f’ct) > 0.4√fc’ and maximum tension loads (ULS) of 19MN
for a pile diameter of 2200mm (cross section of 3.80m2) →
f’ct > 5MPa
Previous experience suggested that the tensile strength of
concrete is about 5-8% of the compressive strength → fc’ ~ 65-
100MPa
Concrete supplier tested 6 samples from an earlier project where
a 70MPa mix achieved 100-110MPa compressive strength after 56
days → f’ct > 6-7MPa
Preparation of a 85MPa concrete mix to target 100-110MPa
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Trial with three mixes
Minimum compressive strength of 85MPa
Minimum tensile strength of 5MPa
Workability of 8-10 hours
All mixes designed not to absorb / release
water from / to environment
Proposed trial mixes for the 85MPa mix
Three different trial mixes:
S851FLL based on workability criteria of 65MPA mix
S851FLLFib with added synthetic fibres (extra tension capacity)
S851FLLretrial with reduced hydration stabilizing admixture
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Concrete workability criteria
Testing if the mix is homogeneous
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Concrete workability criteria trial mixes - S851FLL Fib
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Concrete workability criteria trial mixes - spread test S851FLL Fib
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Concrete workability criteria trial mixes
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Indirect Tensile Strength Test AS1012.10-2000 (Splitting Test)
Taking a sample on site Put sample into test jig under hydraulic
cylinder
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Indirect Tensile Strength Test AS1012.10-2000 (Splitting Test)
Different test set up Sample
in test frame
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Indirect Tensile Strength Test AS1012.10-2000 (Splitting Test)
Stress distribution
Cracked samples
inside a sample
showing typical failure mode
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Results
5 MPa
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Site Trial
Test workability on site on a compression pile (1500mm)
1500mm pile with a plunged column test installation
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Site Trial
Excellent workability criteria for SF851FLL
Plunged column installation up to 10m into concrete (suspend
column)
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Site Trial
Workability criteria for SF851FLL Fib critical
Fibres might get caught on reinforcement cage
or plunged column shear studs
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Site Trial - Summary:
Successful site trial
Risk that fibers get caught on reinforcement cage or plunged
columns considered as too high, fibres reduced workability of the mix
Workability criteria of SF851FLL excellent
Early tensile strength of SF851FLL > 5MPa after 7 days
Early compression strength of SF851FLL > 80MPa after 7 days…
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1500mm
2200mm
1800mm
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
f’c>85MPa
Overview of all piles with high strength concrete (fc’>85MPa)
column
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Tensile Test Results
76 tensile strength results were taken for the whole project:
3 tensile and 3 compressive samples for every 50m3
of 85MPa concrete
2 early strength tests after 2 days: f’ct = 5.2 – 5.4MPa
23 early strength tests after 7 days: f’ct = 4.3 – 6.4MPa
8 strength tests after 28 days: f’ct = 6.6 –
7.5MPa
43 strength tests after 56 days: f’ct = 6.6 –
8.5MPa
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Summary Tensile Strength Results
Summary Tensile Strength Results
0
1
2
3
4
5
6
7
8
9
0 10 20 30 40 50 60Age of probe [days]
Indirect
Tensile
Str
ength
[M
Pa]
test results after 56 days
test results after 7 days
test results after 28 days
Minimum tensile strength requirement of 5MPa after 28 days
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Quality Control – Concrete Displacement Records
theoretical volume
actual volume
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Pile Layout Plan – Integrity Tests
1500mm
2200mm
1800mm
low strain
cross hole
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Quality Control - Cross Hole Sonic Logging
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Quality Control - Cross Hole Sonic Logging
1-5 1-4
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Quality Control – Low strain integrity tests (PIT)
Low strain integrity tests (PIT) to be carried on several piles
randomly
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Lessons Learned
Constant maintenance of drill tools due to high strength rock…
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Lessons Learned
Working under limited access (1/2)
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Lessons Learned
Working under limited access (2/2)
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Lessons Learned
Special challenges when working in Surfers Paradise……
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Future Outlook::
Drilling Technology:
Bauer BG28 used for the SOUL project
machine worked on upper limit
stronger Bauer BG40 rig now available
390kNm torque (+42%)
300kN winch capacity (+20%)
140T operational weight (+48%)
433kW engine power (+22%)
pile Ø3000mm possible
BG28SOUL
BG40
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast
Conclusion:
Use of high strength concrete fc’>85MPa can be used successfully for
bored piles if:
concrete mix is designed & tested for project specific circumstances
concrete supply and delivery without delays
highly experienced site crew and concrete supplier
innovative and cooperative client who is open for new ideas
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Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast