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Technical Proposal

for

Dynamic Compaction Work at Proposed Long Son PertoChemcial Complex, Vietnam

General Content

Section 1 – Bidder Information, Organization

and Key Personnel

Section 2 – Work Experiences

Section 3 – Equipment List

Section 4 – Method Statement

Section 5 – Tentative Work Sequence

Section 6 – QA/QC Plan

CHAPTER 1

Bidder Information, Organization and Key Personnel

KELLER FOUNDATIONS VIETNAM CO., LTD 7th Floor, Nhaxanh building III, 24 Dang Thai Mai

Ward 7, Phu Nhuan District, HCMC Tel: 0835515022, Fax: 0835515023

Website: www.kellerfareast.com

1. General information:

Full Name: KELLER FOUNDATIONS VIETNAM CO., LTD

Business Address:

7th Floor, Nhaxanh building III 24 Dang Thai Mai road, Ward 7 Phu Nhuan District, Ho Chi Minh City Vietnam

Business Category:

Specialized Ground Engineering

Person In Charge: Ir. YEE YEW WENG

Designation: DIRECTOR

E-mail address: [email protected]

Facsimile No.: +84835515023

Phone No.: +84835515022




2. Keller office in Asia

Name & Address Telephone/Facsimile Nos.

Email Address

Representative Name & Position

Business Category

Keller Foundations (SE Asia) Pte Ltd. 18 Boon Lay Way, #04-104, Trade Hub 21 Singapore 609966 Tel: +65 6316 8500 Fax: +65 6316 8652 Mail: [email protected]

Dr. Leong Kam Weng

General Manager

Specialized Ground

Engineering

KELLER (M) SDN. BHD. B5-10, Block B, Plaza Dwitasik, Bandar Sri Permaisuri, Off Jalan Tasik Permaisuri 1, 56000 Kuala Lumpur, Malaysia Tel. +603 9173 3198 Fax: +603 9173 3196 mail: [email protected]

Ir. Yee Yew Weng

General Manager

Specialized Ground

Engineering

Keller Ground Engineering India Pvt. Ltd. First Floor, Eastern Wing, Economist House, S-15, First Cross Road, Industrial Estate, Guindy, Chennai – 600 032. Tel. + 91 44 22501850 Fax:+91 44 2250 1852 mail: [email protected]

Mr. Y. Hari Krishna

General Manager

Specialized Ground

Engineering




3. Parent Company

Full Name: Keller Holding GmbH

Business Category Specialized Ground Engineering

Office Address: Kaiserleistrasse 44, D-63067 Offenbach, Germany

P.O. Box: 10 06 04 / postal code 63006

Telephone No.: + 49 6980510

Email Address: [email protected]

Facsimile No.: + 49 8051270

Capital share held by parent company : 100 %

Name and position of person to be contacted: Dr.-Ing Wolfgang Sondermann, Managing Director




4. Organization KELLER GROUP

Hayward Baker Inc. Keller Ground Engineering Keller Far East Frankipile Australia Pty Ltd.

Case Foundation Company Phi Group Limited Keller (M) Sdn. Bhd. - Malaysia Vibro-Pile (Aust.) Pty Ltd.

McKinney Drilling Company Systems Geotechnique Limited Keller Foundations (SE Asia) Pte Ltd Keller Ground Engineering Pty Ltd.

Suncoast Post-Tension L.P. - Singapore Piling Contractors Pty Ltd.

Anderson Drilling Keller Ground Engineering India Pvt. Ltd.

HJ Foundations - India

Keller Foundations Vietnam Co., Ltd

Keller Middle East

Keller Turki Co. Ltd. - Saudi Arabia

Keller Grundbau GmbH - U.A.E

Keller Grundbau GmbH - Bahrain

Genco Ltd. - Egypt

Continental Europe

Keller Grundbau GmbH - Germany

Keller Fondations Spéciales - France

Keller Grundbau Ges.mbH - Austria

Keller-Terra S.L. - Spain

Keller Polska Sp. Z o.o. - Poland

Keller-MTS AG - Switzerland

Keller Funderingstechnieken B.V

- Netherlands

Keller Fondazioni S.r.l. - Italy

AUSTRALIA

KELLER GROUP PLC.

AMERICA UNITED KINGDOMCONTINENTAL EUROPE,

MIDDLE EAST & ASIA




KELLER FAR EAST

INDIA

Y. Hari Krishna

MANAGING DIRECTOR

Dr. V.R. Raju

DIRECTOR

Ir. Yee Yew Weng

VIETNAM

Ir. Yee Yew Weng

REGIONAL FINANCE

MANAGER

Wong Siew Lai

REGIONAL TECHNICAL

MANAGERSINGAPORE

Dr. Leong Kam Weng

ADMINISTRATION,

FINANCE & HUMAN

RESOURCES

ENGINEERING, TENDER &

MARKETINGCOUNTRY MANAGERS

MALAYSIA

Ir. Yee Yew Weng

Project Orgnization Chart:

Machine Operator Machine Operator

04 Nos - Local 04 Nos - Local

Wheel loader operator Wheel loader operator


Excavator operator Excavator operator

01 No - Local 01 No - Local

General labors General labors


Project Manager

Chua Chai Guan

Project Admin

Site Manager

Le Quang

QA/QC Egn.

Cao Van Nghia

Chief Supervisor

Foong Kham Hong

HSE Officer

(1No - Local)

Technical Advisor

Ernst Freilander (Australia)

DC Specialist

Workshop

Mechanician

Yap

Day shift Supervisor

(1No - Local)

Night shift Supervisor

(1No - Local)

Leading Hand

(1No - Local)

Leading Hand

(1No - Local)

Curriculum Vitae – Ernst Friedlaender

Name: ERNST ANTON FRIEDLAENDER

Qualifications: B Eng (Hons) Professional Affiliations: Member of the South Africa Institute of Civil Engineers.

Fields of Competence:

- Geotechnical Contracting, Design and Construction

Career Summary: Over twenty five years Geotechnical Contracting and Consulting including twelve years as Founder and General Manager of Geofranki in South Africa and developing and introducing specialist geotechnical systems into South Africa, Indian Ocean Islands and Australia

Professional Experience:

2004- current 2000 - 2003

KELLER GROUND ENGINEERING, AUSTRALIA Managing Director Established Specialist Soil Improvement company for Keller Australia to compliment the piling services of the Keller companies Frankipile and Vibropile in Australia. Focusing initially on Soil Improvement techniques including Dynamic Compaction and Replacement and Jet Grouting applications in addition to traditional Vibro-flotation services in the local market AUSTRESS FREYSSINET – MENARD , AUSTRALIA Manager-Specialist Geotechnical Projects

Responsible for all Geotechnical activities of Austress Freyssinet – Menard in Australia and surrounding territories. Introduced Jet Grouting, and developed the Dynamic Compaction and Dynamic Replacement market in Australia, extended the specialist Geotechnical activities of Austress Freyssinet into Indonesia


1987-1999 1985-1986

GEOFRANKI , SOUTH AFRICA. General Manager Director -Franki Africa Founded Geofranki, as a division of Frankipile SA. Specialized in anchoring, grouting and soil-improvement systems. Introduced Soil Nailing to Southern Africa. Developed Dynamic Compaction as a general Soil Improvement technique in Southern Africa. Engineered and managed in excess of 200 Dynamic Compaction and Replacement projects in Southern Africa and the Indian Ocean Island Carried out extensive grouting projects including stabilization of undermined land, compaction grouting and chemical grouting. SCHWARTZ TROMP AND ASSOCIATES, SOUTH AFRICA.

Consulting, design engineer Specialized in lateral support, piling and anchor design and Compaction Grouting. Assisted in the compilation of the Code of Practice for Lateral Support for the South African institute of Civil Engineers.

1981-1985 1979-1980

GROUND ENGINEERING AND PILING, SOUTH AFRICA.

Site Engineer Junior Engineer on 50 Anchoring Projects, both permanent and temporary utilising post grouting systems, under supervision of Dr R Parry Davies and in specialist applications, Dr S Littlejohn. Developed specialist T.A.M. grouting systems and trialed and implemented 80,000m3 compaction grouting project under guidance of Technical Director Mr D McColl in Dolomite profile. Managed 90,000m2 Dynamic Compaction projects in collapsible aeolean sands for joint Menard-Ground Engineering Joint Venture. Chemical and T.A.M. grouting projects for the MTR in Hong Kong under Dr D Bruce in Colcrete-Ground Engineering Joint Venture

GRUNER AG BASEL, SWITZERLAND.

Exchange Student

Primarily site supervision of environmental, basement excavation and lateral support projects.


DYNAMIC COMPACTION EXPERIENCE In the mid 1980’s I was in charge of a large Dynamic Compaction contract carried out in joint venture between Menard and Ground Engineering and Piling. The project involved the treatment of deep aeoelean sands with high collapse potential. The dry soils unexpectedly did not respond to conventional DC treatment. After extended on site trials a technique was developed to overcome the site conditions and the project was successfully completed. Based on the experience of this project, and with the formation of Geofranki, we introduced a revised DC treatment system to Southern Africa market independent of outside technical input. The success of these projects resulted in a the establishment of a significant Dynamic Compaction market in Southern Africa with the order 200 projects successfully completed in the following decade. Geofranki, through its in-house capabilities still maintained a market share of the order of 95% of this market. Significant projects, under site conditions similar to PLDC, completed in this period include: The Randburg Waterfront- Johannesburg- A 35,000m2 development on a 12 m deep brick quarry backfilled with sands, Dynamically treated to allow the construction of a commercial development around a man made lake. Makro Wholesale Centre- Germiston- A 50,000m2 shopping centre developed on 11 m deep quarry, previously used as an industrial dump site. Mozal Aluminium Smelter- Mozambique- Treatment of 160,000m2 of 4 to 8 m deep collapsible sands for the construction of an aluminium smelter in Maputo, Mozambique. Hill Fox Center- Johannesburg- Compaction of fine grained fills in a 10 m deep disused quarry to for the construction of a retail outlet. Optimum Mine- Railway crossing- Eastern Transvaal- The treatment of 20m deep fills over reclaimed open-cast mine areas, after the original rail construction displayed settlements in excess of 300mm prior to opening of the railway line. Freeport Development – Mauritius - The treatment of 8m deep fills and underlying alluvial deposits on reclaimed land for the new Freeport development in Port Lois, Mauritius. Since arriving in Australia in 2000 , I initiated, managed and engineered the following DC projects in Australia for Austress Freyssinet in Joint Venture with Menard, Breakfast Creek Bridge Abutment – Brisbane – Dynamic Replacement treatment of 12m deep clays for a 6 m high bridge abutment . Varsity Lakes Development- Gold Coast – Dynamic Compaction/Replacement treatment of 2 to 8 m deep sands and clays for a retail outlet in Bermuda Street on the Gold Coast. Manns Road Retail Outlet- Gosford – Dynamic Compaction and Replacement of fills and soft clays on the site of a disused tannery in Gosford. This project was carried out in two phases, with additional work awarded based on the success of the first phase. Montefiore Street- Fairland- Melbourne- Dynamic Compaction of a 12 m deep backfilled brick-pit, for the construction of an industrial office block and warehouse. This work was carried out in an established industrial township. Mount Arthur Mine- Central Coat NSW – Dynamic Compaction of reclaimed open cast mine areas for the construction of a hopper-conveyor


Townsville Sugarsheds- Queensland – DC and DR treatment of reclaimed land and soft alluvial soils for the construction of 40,000 m2 sugar storage under 180 kPa loading. ( This project was managed on site by French staff provided by Menard) Mascot Airport – Sydney Sewer repair- A small DC project stabilizing suspected voids in sands above a deep a main sewer line after remedial work by relining and jet-grout underpinning. Aerlie Beach – Queensland Dynamic Compaction treatment of waste-rock fill over 18,000m2 as soil improvement to enable construction of upmarket apartment building s on a disused quarry. Meriton Apartments – Sydney Dynamic Compaction of loose sands overlying clays to provide suitable founding conditions for a raft slab foundation for a 10 storey apartment building, Gateway Bridge Widening and Access Roads – Brisbane Dynamic Replacement treatment of soft clays and landfill waste to enable construction of access roads and abutments on major road upgrade in Brisbane.

CURRICULUM VITAE

NAME

DATE OF BIRTH

NATIONALITY

PROFESSION

LANGUAGES

IR. CHUA CHAI GUAN

February 20, 1972

Malaysian

Geotechnical Engineer

Malay, English, Mandarin

PRESENT POSITION Technical Manager

Education

1993 - 1997

2000-2001

Experience

Universiti Sains Malaysia

Nanyang Technological

University

Civil Engineering

Geotechnical

B.Eng (Hons)

M.Eng.

Joined KELLER (M) SDN BHD in : February 2006

2007 till present in Malaysia

2006 till 2007 in Malaysia

Joined Sealand Teknikal Sdn Bhd in 2005

2005 in Malaysia

Joined Macroworks Sdn Bhd in 2002

2002 - 2005 in Malaysia

Tender, Design, Marketing of major

Ground Improvement Works

Tender, Design, Execution of major

Ground Improvement Works using

Tender, Design, Execution of

infrastructure Works

Technical

Manager

Senior

Geotechnical

Engineer

Senior Geotechnical

Engineer

Project Management and Audit for the

following major projects

Executive Engineer

a) The Construction & Completion of Sapangar Bat Container Port Sapangar Bay, Kota Kinabalu.

b) Projek Gerbang Selatan Bersepadu -CIQ Main Buildings, JB Sentral,

Interchange No.l, PUB Relocation, Road Bridge, Rail Bridge & Navigation Channel

Dynamic compaction/ vibro technique

Grouting and soil mixing

Joined Arup Singapore Pte Ltd in 2001

c) Cadangan Pengubahsuaian

Panggung Eksperimen Untuk Pusat Kebudayaan Universiti Malaya, Kuala Lumpur

2001 - 2002 in Singapore/Hong Kong Design & supervision of geotechnical Geotechnical

works for various major projects :- Engineer

a) Piling Works for Proposed 77 units Terrace Housing at Upper Aljunide Road

b) Proposed Construction of Kuala Kedah Marina Harbour, Malaysia

c) Proposed Drainage Improvement at Serangoon Road/Race Course Road/Penang Lane, at Dover Close East and Upstream of Sungei Api-Api

d)Slope Stabilization at 700 Woodlands Road

e) Proposed erection of a condominium housing development at Evelyn Road/Newton Road

d) Wanchai Church Development of Hong Kong

e)Northen Island Link (NIL) of Hong Kong

f)SIP Phase IV, Package 3-S14IIIa -Lingnan Dr. Chung Wing Kwong Memorial Secondary School (Group 1 School). Hong Kong

Joined Arup Jururunding in 1997

1997 -1999 Malaysia/Bangkok

works for various major projects

a) Proposed Development of Plaza

Merdeka, Kuala Lumpur.

b) Proposed Pacific Bank HQ, Jalan Sultan Ismail, Kuala Lumpur.

c) Independent assessment of damages to Confucius Secondary School during neighbouring construction of UDA Hotel for UDA.

d)Proposed Gurthrie Corridor Expressway

Design & supervision of geotechnical Geotechnical

Engineer

(25 Km).

e) Proposed 600 room hotel, Genting Highlands.

f)MRTA Initial System Project Underground Structures, North Contract, Bangkok, Thailand.

Professional Activities

1. Author of more than 10 technical papers on geotechnical engineering.

2. The 2004 Hulme First Prize Winner in Singapore. [The Hulme Prize was set up by

Tunnelling and Underground Construction Society (Singapore), TUCSS in 1999 to honour

Terry Hulme, Honorary Member of TUCSS, for his outstanding contribution to TUCSS and

Tunnelling in Singapore].

CURRICULUM VITAE

NAME : PENMETSA SREENIVASA RAJU

DATE OF BIRTH : March 1, 1970

NATIONALITY : Indian

PROFESSION : Geotechnical Engineer

LANGUAGES : English, Telugu (Mother Tongue)

PRESENT POSITION : Senior Project Manager

Education

1981 - 1985 Andhra Pradesh, India High School Education SSC (FormV)

1985- 1988 Tanuku, A.P., India Civil Diploma in Civil

Engineering

1988 -1992 Kakinada, A.P., India Civil A.M.I.E (B.E.)

(A.M.I.E = Assioate Member of Institution of Engineers (India) equivalent to Bachelor of Engineering)

Experience

Joined KELLER (M) SDN BHD in : 19 January 1996

2007 to Present

1996 to 2006

1993 to 1995

1990

KELLER (M) SDN BHD

MALAYSIA

KELLER (M) SDN BHD

MALAYSIA

INDUSTRIAL

CONSULTANCY &

SPONSORED

RESEARCH CENTRE,

IIT, MADRAS

OIL & NATURAL GAS

COMMISSION, INDIA

Stone Columns, Sand

Compaction & Deep Soil

Mixing / Grouting

Stone Columns, Sand

Compaction & Deep Soil

Mixing

Construction of Effluent

Treatment Plants

Construction of Heavy

Storage Platforms

Senior Project

Manager

Geotechnical

Engineer & Project

Manager

Project Associate

Site Supervisor

Dynamic Compaction

CURRICULUM VITAE

NAME

DATE OF BIRTH

NATIONALITY

PROFESSION

LANGUAGES

PRESENT POSITION

SAW HONG SEIK

September 30,1977

Malaysian

Civil Engineer

English, Malay, Mandarin

Sr.Geotechnical Engineer

Education

YEAR PLACE OF STUDY FIELD OF STUDY DEGREE

1999-1995 S.M.St. Michael

1995 -1998 Politeknik Ungku Omar Ipoh

1999 - 2002 University Kebangsaan Malaysia, Bangi

Secondary School Education

Civil Engineering

Civil & Structural Engineering

Form 5

Diploma

Bachelor of Science

Experience

YEAR PLACE OF WORK DESCRIPTION OF WORK EMPLOYED AS

Joined KELLER (M) SDN. BHD. In : April 2002

1998 - 1999 Ganding Bahu S/B * Construction of RC box culvert Site Supervisor * Construction of RC evevated water tank

* Construction of 52 nos. Terrace house, 8 nos. Semi-D & 6 nos. Bangalow

2002 Keller (M) S/B * Vibro Replacement at KRR-lnterchange H Geotechnical Engineer * Vibro Replacement at NPH-Taman Desa

Interchange * Design check of Vibro Replacement for

NPH-Pantai Dalam Interchange

* Design check of Vibro Replacement for BR6, BR11, BR15, Area 25 for Ipoh-Rawang Double Tracking

* Grouting works at SMART * Vibro Replacement (Vibro Stone Column and

Vibro Concrete Column) and Deep Soil Mixing at Jelutong Sewage Treatment Plant

* Vibro Replacement at Third Lane Widening, North South Highway between Rawang and Tg. Malim

* Deep Soil Mixing at Heritage Square, Malacca * Vibro Replacement at Tg. Langsat Port * Vibro Replacement at Jimah Power Plant * Deep Soil Mixing at Sentosa Integrated Resort, Singapore

CURRICULUM VITAE

NAME

DATE OF BIRTH

NATIONALITY

PROFESSION

LANGUAGES

PRESENT POSITION

LE HONG QUANG

November, 25th 1979

Vietnamese

Civil Engineer

English, Vietnamese

Sr. Construction Engineer

Education

YEAR PLACE OF STUDY FIELD OF STUDY DEGREE

1991-1997 Quoc Hoc High school

1997- 2002 Univerisy of technology

Secondary and high School

Civil Engineering

High school

Bachelor of Engineering

Experience


Joined KELLER (M) SDN. BHD. In : Jan 2008

2002 – 2004 PCC4 * Construction of Phu Quoc power plant Site Manager* Construction of Phu Huu 220 KVA power

* Construction of Trang Bang 220 KVA powerTransformer yard

2004 – 2006 KTOM JV Work for Tan Son Nhat Int AirPort Project Site Engineer

Ho Chi Minh City

Transformer yard

* Site Engineer for Passenger Terminal Building: Control and supervise structure works* In charge of Post – tensioning system and rebar threading works ( VSL sub-contractor scope)* In charge finishing work : Masonry, Ceiling , Roofing, Door frame, Tiling …* QA/QC for Central Plant and Sewage Treatment Plant

2006 - 2008 Vinci Construction Work for Camau Power Plant Project Chief Site Engineer

* Control constructions area, Piling works, Foundation works and structure work of Power Block ( Gas Turbine Foundation, Steam Turbine Foundation, By pass Stack, The Transformer…..), building , oil tank, Intake channel, pumping station …* Coordinate and arrange site staffs to ensure work progress with quality and safety * Making report to superintendant


2008 - Now Keller Malaysia Vietnam and Malaysia Project Construction Engineer

* Vibro stone columns for Ipoh – Badang Besar double track Project * Vibro stone columns for Interflour Vietnam Project* Dynamic Compaction/ Replacement for East Coast high way

CHAPTER 2

Work Experiences

Keller International’s Dynamic

Compaction/Replacement Track Record

Year Job Title

Keller South East Asia

1983 Tampines Avenue 12, Ground Treatment for Bridge Approaches,

Singapore

1984-1985

Paya Lebar Airbase, Ground Treatment for Storage Facility

Foundations, Singapore

2008 East Coast Expressway Phase II (LPT 2), Malaysia

Keller German

1996 M1/A1 highway, Ground treatment for roads and bridges, UK

1998 Calcot Commercial Park, Treatment of a 32 acre landfill,

California, USA

1999 Lugteich Mining Pond, Stabilization of slopes, 1.3mio m3 soil

treated, Germany

2002-2004 Mining pond and dump Mastkippe Kleinleipisch, Stabilization of

dump area, 1.9 mio. m3 soil treated, Germany

Hayward Baker USA

1984 Steel Creek Dam, USA

1985 PARK CENTRE PARCEL, USA

1985 Steel Creek III, USA

1985 SWFLANT FACILITY.KB, USA

1985 AVENAL STATE PRISON, USA

1987 RIVERSIDE FLOOD CONTROL, USA

1990 MEDLEY LANDFILL, USA

1991 POTTSTOWN LANDFILL, USA

1993 CANE ISL COMP TURB PLANT, USA

1995 ASW BAR MILL, USA

1995 SAM'S CLUB, USA

1996 DART BUS FACILITY, USA

1996 ADULT DETENTION COMPLEX, USA

1996 INLAND STEEL - DDC, USA

1998 CALCOT, USA

1999 MIRAGE CASINO, USA

1999 James D. Mason Intermodal Facility, USA

1999 Dollar General Distribution Center, USA

2000 Brentwood WWTP, USA

2000 San Francisco Muni Metro East, USA

2001 N.T.C. San Diego, USA

2001 Redding Power Plant, USA

2001 Pier 400 Group II DDC, USA

2002 Sunset Hills Elementary School, USA

2004 Riverpark Development, USA

2004 Tempe Marketplace, USA

Keller Australia

2004 Aerlie Beach – Queensland .Dynamic Compaction treatment of

waste-rock fill over 18,000m2 as soil improvement to enable

construction of upmarket apartment building s on a disused

quarry.

2005 Meriton Apartments – Sydney. Dynamic Compaction of loose

sands overlying clays to provide suitable founding conditions for a

raft slab foundation for a 10 storey apartment building.

2006 Gateway Bridge Widening and Access Roads – Brisbane. Dynamic

Replacement treatment of soft clays and landfill waste to enable

construction of access roads and abutments on major road upgrade

in Brisbane.

Client

Public Works Department (Jabatan Kerja Raya, JKR)

Malaysian Highway Authority - (Package-10 only)

Main Contractor MTD Construction Sdn Bhd.

- (Package 10) Tidal Marine Engineering Sdn. Bhd. - (Package 2 & 3 only)

Cergas Murni Sdn. Bhd. - (Package 9A) GPQ-Bukit Puteri JV - (Package 11)

TSR Bina Sdn. Bhd. - (Package 12)

Project Details Area: 451,800 m2

Execution Period 2006 to 2009 Executing Branch

Keller (M) Sdn. Bhd B5-10, Block B, Plaza Dwitasik, Bandar Sri Permaisuri,

Off Jalan Permaisuri 1, 56000 Kuala Lumpur, Malaysia Tel: +60 3 9173 3198

Fax: +60 3 9173 3196 E-mail: [email protected] www.kellerfareast.com

Ground Improvement Techniques for

East Coast Expressway Phase II (LPT 2), Malaysia

Project The East Coast Expressway Phase II is 190km long and it runs from Jabur

Interchange to Kuala Terengganu. The project was demarcated and awarded as 12 separate sub-packages. Ground treatment was instituted

where the highway passes through areas of swampy ground and soft alluvial sediments. The objectives are to ensure embankment stability and

to restrict settlements within acceptable limits. The project is expected to be completed by 2010.

Soil Condition

Typically, soft ground comprises silty clay (cu = 10 to 15 kPa) down to

varying depth. In general, water content is 50 – 60% and plasticity index 20 – 30%.

Solution

Several types of ground improvement techniques were implemented which included removal and replacement; vertical drains and surcharging; vibro

sand and stone columns; and dynamic replacement, to meet the stability and settlement criteria of proposed structures. Keller was involved in the

design and execution of part of these works at the following packages:

Package 2 – Vibro Stone Columns – 46,000 m2

Package 3 – Vibro Stone Columns – 27,700 m2

- Dynamic Replacement – 131,300 m2

Package 9A - Vibro Stone Columns – 21,600 m2

Package 10 - Vibro Sand Columns – 9,500 m2

- Vibro Stone Columns – 142,700 m2

- Dynamic Replacement – 9,700 m2

- Prefabricated Vertical Drains – 30,700 m2

Package 11 - Vibro Stone Columns – 23,500 m2

Package 12 - Vibro Stone Columns – 9,100 m2

Prefabricated Vertical Drains

installation in progress

Vibrocat were involved for vibro

stone column and vibro sand column works

Automated Keller DR crane

Construction

The ground improvement works commenced in Sept’06 and are expected to be completed by March’09. At the peak of construction, the machineries

involved included 5 nos. Vibrocat, 3 nos. Alpha-S, 2 nos. PVD rigs and 3 nos. DR rigs. Due to environmental sensitivities, all the stone columns

were installed using “dry” method. Ground treatment was carried out from top of the working platform to the roof of stiff to very stiff clayey silt. This

ranges from 4m to 18m deep. The embankments were fully instrumented and monitored during the filling and rest period of the embankment.

Crane-hung Alpha-S system for vibro replacement method

Dynamic Replacement crane during installation

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KProjectProject :: BALTIC ARENA IN GDAŃSKBALTIC ARENA IN GDAŃSK

ClientClient:: WAKOZ SP.Z O.O. (BIEG 2012)WAKOZ SP.Z O.O. (BIEG 2012)

PhasePhase:: Under construction (completion June Under construction (completion June

Final productFinal product:: VibroflotationVibroflotation

AreaArea:: ~ 90 000 m~ 90 000 m

TaskTask:: Achieving cone resistance qAchieving cone resistance q

Reduction of foundation settlements ∆s ≤ 1,0 cmReduction of foundation settlements ∆s ≤ 1,0 cm

Soil Soil conditonsconditons / Loads: / Loads: Moderate dense and Moderate dense and

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KBALTIC ARENA IN GDAŃSKBALTIC ARENA IN GDAŃSK

WAKOZ SP.Z O.O. (BIEG 2012)WAKOZ SP.Z O.O. (BIEG 2012)

Under construction (completion June Under construction (completion June 202009)09)

VibroflotationVibroflotation and Dynamic and Dynamic CompationCompation

~ 90 000 m~ 90 000 m22

Achieving cone resistance qAchieving cone resistance qcc ≥ 15 ≥ 15 MPaMPa

Reduction of foundation settlements ∆s ≤ 1,0 cmReduction of foundation settlements ∆s ≤ 1,0 cm

Moderate dense and Moderate dense and siltysilty sands / σ ≈ 300 sands / σ ≈ 300 kPakPa

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Few photos from the site. Few photos from the site. (1.Preparing working platform, 2.Vibroflotation, 3.Dynamic Compaction)(1.Preparing working platform, 2.Vibroflotation, 3.Dynamic Compaction)

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(1.Preparing working platform, 2.Vibroflotation, 3.Dynamic Compaction)(1.Preparing working platform, 2.Vibroflotation, 3.Dynamic Compaction)

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NCIG CET3 COAL

STOCKYARD

GROUND IMPROVEMENT USING DYNAMIC REPLACEMENT FOR NCIG CET3

COAL STOCKYARD

Charles CH Chua (Connell Hatch, Australia)

Ming Lai (Keller Ground Engineering Pty Ltd)

Graeme Hoffmann (Keller Ground Engineering Pty Ltd)

Brett Hawkins (Connell Hatch, Australia)

Abstract

This paper presents an overview of the geotechnical design considerations and various analytical work undertaken for

the development of the 30 mega-ton per annum (Mtpa) coal stockyard area at the Coal Export Terminal 3 (CET3) on

Kooragang Island, NSW. The coal stockyard of CET3 covers an area approximately 1.2km long by 300m wide. The site

is underlain by soft compressible soil strata of variable thickness.

To support the 21m high coal stockpiles and the stacker-reclaimer machinery loads, the upper ground required

stabilisation/consolidation improvement. The original design of the proposed ground improvement was to use dredged

sand fill won from the proposed berth and wharf facilities constructed for the project to progressively preload the

ground and eliminate the majority of the stability concerns and consolidation settlements during the construction period.

However, due to programme constraints and availability of dredged sand material, ground improvement by dynamic

replacement (DR) was employed to reduce construction time and need for preload material.

The project, believed to be the largest DR project completed in the Southern Hemisphere to date, was contracted to

ground improvement specialist, Keller Ground Engineering on a design and construct basis, based on performance

criteria to limit the post-construction settlements and satisfy the settlement criteria for machinery operation

considerations.

The process of the dynamic replacement work and construction constraints of the ground improvement technique are

presented.

1 INTRODUCTION

The Coal Export Terminal 3 (CET3) development on Kooragang Island, NSW, consists of a stockyard area measuring

approximately 1.2km in length and 300m in width. The 30Mtpa coal stockyard area requires ground improvement to

treat the subsurface soils for the future loadings. The coal stockyard will need to support 21m high coal stockpiles and

also coal stacker-reclaimer machinery traversing on 4.5m high machinery berms. Dynamic replacement was employed

to improve the ground characteristics for the future operational loads.

The layout of the various elements of the development is shown on Figure 1, comprising three coal pads stockpiles, two

machine berms and one containment berm. The area of ground improvement is divided into 30L, 30C and 30R as

shown on Figure 1.

During the feasibility design stage, the proposed ground improvement to the foundation soils involved preload

treatment of the soft soils to manage foundation stability and induce consolidation settlement under controlled

surcharge. Due to the construction program constraints and availability of fill material, the preloading option was

deemed unsuitable. Preloading the stockyard in stages and other alternative methods of ground improvement were

examined. However this preloading process had its drawbacks in that not only did it involve massive earthworks to

place the preload material but the potentially costly and time consuming task of removing the preload material also

needs to be carefully considered to render it practical.

Various types of ground improvement techniques were examined with specialist ground engineering contractors to

identify a technique most suitable for the stockyard area. Dynamic replacement was accepted to be the solution to

improve the upper soft strata to nominal depths of 6m. Due to the presence of a thick sand stratum of varying layer

thickness from 10m to 30m, ground treatment beyond this sand stratum was not considered practical. The total and

differential settlements of the lower clay have been evaluated and found to be within the design criteria. In addition,

these settlements will be managed via regular re-ballasting after the coal export terminal turns operational.

This paper presents a general description of the treatment method, which comprises the adopted design philosophy, the

verification and construction work, and post construction testing.

Figure 1: NCIG CET3 Stockyard

2 GROUND CONDITIONS

A series of cone penetration testing (CPT) and borehole investigation was carried out by Connell-Hatch prior to the

awarding of the contract. This was supplemented by additional CPT testing after the awarding of the contract to Keller.

These soil investigations indicate that soft compressible soil strata of variable thickness underlie the site. A typical

result of pre-construction CPT testing is shown in Figure 2.

Figure 2: Typical Pre-Construction CPT Result

The existing ground levels vary between RL+4 on the east to RL+1 on the west. The ground conditions of the eastern

half of the stockyard area generally consist of 2m of very loose to medium dense sandy fill overlying 2m to 3m of soft

clay. Underneath the soft clay, medium dense to dense sand is intersected before rock is encountered at approximately

RL-10.

For the western half of the stockyard, the thickness of sandfill diminishes and soft clay was intersected at the surface in

some locations. The rockhead dips significantly towards the westerly direction. Below the medium dense to dense sand

underlying the soft clay layer at the top, a layer of stiff to very stiff clay members are encountered at approximately RL-

30, and extended to a depth of nominally RL-40.

The groundwater table is generally at 1 to 4m below the existing ground surface at the 30R and 30C areas. At 30L, the

groundwater is 0 to 2m below the existing ground surface. Generally the DR columns are expected to be 4 to 6m in

length extending up to 1m into the medium dense to dense sand layer.

3 STRUCTURES & LOADINGS

It was proposed that sand material to be placed onto the improved ground to form a platform up to nominally RL+7 at

the eastern end (30R) to nominally RL+4 at the western end (30L) before stacker reclaimer berms are constructed. The

construction of the platform will involve placement of sand by hydraulic means and then, once the design levels for the

top of platform are achieved, compacted by numerous passes of impact rolling equipment.

On the platform, stacker reclaimer berms of typical height 4.6m will be installed using geotextiles and sand material. At

the stacker reclaimer berms, dead and live loads from the machinery (amounting to 120kPa) need to be considered. The

improved ground needs to support up to 21m of coal stockpiles in the coal pads during operation.

A construction surcharge of 20kPa was considered in the design.

4 CRITERIA

After the dynamic replacement, the improved ground is required to remain serviceable during construction and

operation by limiting settlements and ground movements to tolerable limits, as specified in the Table 1 below:

Table 1: Limiting Criteria for Improved Ground after Treatment

Coal Pad (Load=210kPa) &

Stockpile Containment Berm

Limiting Value

Vertical settlement (mm) 200

Horizontal displacement (mm) 25

Stacker Reclaimer Berm (Load=120kPa) Limiting Value

Vertical settlement (mm) 150

Horizontal displacement (mm) 25

Differential settlement V: 1/500 over a 25m chord

H: 1/1500 over a 8m chord

Tilting (%) 0.3

The stability of the ground including berms in the stockyard needed to achieve minimum factors of safety of 1.5 and 1.1

in the long-term static and seismic loadcases respectively. For the short-term, a minimum factor of safety of 1.3 was

required.

5 GROUND IMPROVEMENT

5.1 DYNAMIC REPLACEMENT METHOD

It was expected that without treatment, the resultant settlement from the soft clay layer, within the first 5m, could be

excessive and there is potential for slip failure due to the loadings from the Coal Pads and Stacker Reclaimer Berms.

Due to the shallow treatment depth, dynamic replacement method has been chosen as the most suitable treatment

method for the soft clay layer on site.

Dynamic replacement is a technique that combines the features of dynamic compaction (dropping of a heavy weight

(pounder) from a substantial height to cause deep compaction of the ground) and vibro-replacement (commonly referred

to as stone columns where gravel columns are installed using a vibrating probe to increase the stiffness and strength of

the ground). In the dynamic replacement process, compacted columns made of stone or sand, are installed into the

ground by a pounder dropped repeatedly onto a stone/sand layer. The craters created as a result of the impact is

backfilled with stone/sand during the installation process. A typical installation process is shown in Figure 3.

Figure 3: Dynamic Replacement

Upon completion of the installation process, a compacted column of stone/sand is left in the ground, surrounded by a

soil/stone/sand matrix of increased density. The columns and the in-situ soils form an integrated system having low

compressibility and high shear strength. The excess pore water pressure can dissipate through the column, which also

acts as a vertical drain. The settlement expected for the treated soil is reduced while the rate of settlement is increased

when compared with the untreated soils.

The degree of improvement (settlement reduction and increased shear strength) achieved by the dynamic replacement

process depends on the soils being treated, the impact energy, the diameter of the columns installed and the installation

spacing.

5.2 DESIGN

The aim of the ground improvement using dynamic replacement is to:

a. Improve the deformation modulus of the treated soils to reduce the potential settlement within tolerable

limits;

b. Increase the shear strength of the treated soils to ensure stability of the proposed coal pads and stacker

reclaimer berms during construction and operation.

To achieve the above objectives, the design process was carried out with the assistance of:

i. Greta – assessment of ground improvement parameters;

ii. SlopeW – assessment of the slope stability of the proposed geometric configurations;

iii. Plaxis – finite element method to assess overall settlement effects of various loadings and tilt.

5.2.1 Greta Improvement Analysis

The Greta software program is the ground improvement program developed and used by Keller. It uses the theory

presented in the Priebe’s method (1) to assess the degree of improvement achieved by the DR method. The method has

been well accepted in Europe and Asia for many years and proven to provide a suitable and reliable ground

improvement analyses.

The design method refers to the improving effect of the columns in a soil which for design purposes is considered to be

unaltered from its initial state. Firstly, an improvement factor is established based on the improved performance of the

subsoil in comparison to the state without columns. According to this improvement factor, the deformation modulus of

the composite system is increased and settlements are reduced. All further design steps refer to this basic value. The

typical basic improvement factor no, as a function of replacement ratio (A/Ac) and friction angle of the column material

φc, is shown on Figure 4. A is defined as the tributary area for each DR column while Ac is the cross-sectional area of

DR column. With the various adjustments that take into account the compressibility of the columns, the density of the

surrounding soils and the columns, and the founding layer of the column, a final improvement factor is established

whereby the soil modulus is increased resulting in reduced settlements.

Figure 4: Improvement Factor versus Area Ratio for different Friction Angles

(µs is the Poisson’s ratio of the column material)

In many practical cases the reinforcing effect of the columns is superposed with the densifying effect of dynamic

compaction, i.e. the installation of the columns often densifies the soil in-between. However, this effect is

conservatively ignored in most cases.

Using the above design concepts, the adopted dynamic replacement configurations can be summarised in Table 2.

Table 2: Configurations for Compacted Sand Column and proposed Structural Elements

Description Diameter (m) Spacing (m)

Sand Columns ≥ 2.5m 5.0m to 6.0m

5.2.2 SlopeW analysis

The shear performance of ground improved by dynamic replacement is most favourable. While under shear stress more

rigid elements may break successively, sand columns deform under load and any overload is transferred to

neighbouring columns. The columns receive an increased portion of the total load, which depends on the area ratio of

the proposed configurations. According to the proportional loads on columns and soil, the shear resistance from friction

of the composite system can be readily averaged. Similarly, the cohesion of the composite system is also obtained from

the proportional loads.

The calculated composite parameters of friction angle and cohesion are input parameters for SlopeW, a limit

equilibrium analysis utilising the Bishop Simplified method, to assess the stability of two configurations:

a. Internal Stacker Reclaimer Berm and Coal Pads;

b. External containment berm and coal pads.

For the consideration of the earthquake condition, an acceleration coefficient of 0.16g has been used in the stability

analyses of the improved ground. The region is an area of low to moderate seismicity and lies within an intra-plate

area. A significant earthquake occurred in December 1989, which registered approx. 5.6 on the Richter Scale and was

assessed to have a return period of 500 years.

Figure 5 shows a typical result of the slope stability analyses through the most critical section.

Figure 5: Slope Stability Analysis using SlopeW

5.2.3 Plaxis Analysis

The improved engineering parameters such as strength and elastic modulus of the treated ground are used in a finite

element program, Plaxis, to assess the overall interaction on settlement of the various coal pads and stacker reclaimer

berms.

The results show that the specified criteria are satisfied with the adopted dynamic replacement configurations. For the

30R area, the predicted maximum vertical settlements are approximately 170mm and 40mm, occurring under the triple

cone coal pad and stacker-reclaimer berms respectively. For the sensitive stacker-reclaimer berms, the expected

differential vertical settlement over a 25m chord is 1 in 1470 with tilt of 0.26%. The expected differential horizontal

settlement over a 8m chord is 1 in 2285.

5.3 VERIFICATION

As part of the specification for the improvement work, verification testing is to be carried out. The aims of the

verification tests are:

a. To confirm the parameters adopted for the design, or to use the achievable parameters to revise the design

accordingly;

b. To establish construction configurations that will allow the objectives of the project to be met.

The variables in the construction parameters include:

i. Pounders dimensions of size and weight;

ii. Number and height of drops;

iii. Phasing of the energy input and requirement of an ironing pass.

The construction parameters of the dynamic replacement have been varied to arrive at an optimum configuration to

achieve the objectives of the project in terms of technical criterion and program.

To determine the achieved end products and to establish the optimum construction parameters, the following

verification tests have been carried out:

i. Post treatment Cone Penetration Test, CPT – to determine the column soil parameters and diameter;

ii. Plate Load Test, PLT – to assess the load carrying capacity deformation of the columns under uniaxial

load;

iii. Dilatometer Testing, DMT – to determine the constructed elastic modulus of the columns and to establish

a correlation with the CPT results.

5.3.1 Post treatment Cone Penetration Test, CPT

Post treatment CPTs have been carried out on selected columns as varying distances from the surveyed centre of the

columns. Typical results of two columns are shown on Figure 6.

Figure 6: Cone Penetration Test results at column locations before and after DR treatment.

Based on the results of these tests, it can be concluded that a column diameter of at least 3.3m is achieved to a depth of

3m. Beyond this depth, a column diameter of nominally 2.5m had been measured.

Correlations as proposed by Jamiolkowski et al. (1985) and Schmertmann, (1978), have been used to assess the friction

angle of the constructed columns, using the post treatment CPTs. The results indicate that a friction angle of 36o to 40o

can be expected. This result is confirmed by the Dilatometer test (DMT) detailed later.

5.3.2 Plate Load Test

Plate load tests (PLT) were carried out on selected columns. The diameter of plate used is 1.2m diameter. Working

loads (WL) of the columns for the plate load test are determined as:

� Stacker Reclaimer Berm – 185kPa = 209kN or 21ton

� Coal Pads and Containment Berm – 270kPa = 305kN 0r 31ton

The maximum loads tested for the columns were 1.1 to 1.5 times the working load of the column.

Counter-weight for the tests was provided by the dynamic replacement crane (weighing 110ton). Results of the plate

load tests are presented in Figure 7, which was tested to a maximum pressure of 405kPa, or an equivalent load of 46ton.

Figure 7: Plate Load Test results

While the plate load can only test the column to a depth of about 2 times the diameter of the plate, it can be used to

approximate the stiffness (elastic modulus) of the column. For the calculation of the stiffness of the columns, the slope

up to 100% WL, has been assessed as this represent the condition at the serviceability condition of the columns, in

which settlements are estimated. Together with the CPT testing carried out on the completed columns, a preliminary

correlation is established between the results of CPT and PLT, which gives the following approximate relationship:

E = 3qc (MPa) ----------------------- (1)

The estimated column stiffness from the above equation is presented in Table 3.

Table 3: Interpreted Elastic Modulus of Dynamic Replacement Columns

Depth Soil Condition Average qc (MPa) Interpreted E (MPa)

0m – 2m Sand 8.0 24.0

2m – 4m Clay 7.0 21.0

4m – 5m Sand 15.0 45.0

5.3.3 Dilatometer Test

Dilatometer tests (DMT) were carried out to determine or confirm the following:

i. The friction angle of the completed column;

ii. The constraint modulus (Ds) and hence the elastic modulus (E = 0.8Ds) of the column;

iii. A correlation between the elastic modulus determined from DMT with the cone penetration resistance qc.

Figure 8 shows selected dilatometer tests with the calculated friction angle. It can be seen that the measured/correlated

friction angles are generally higher than 36o as assumed in the design.

Column 1998

Column 2023

Figure 8: DMT results for Columns 1998 & 2023

Selected results of the elastic modulus estimated from the DMT and the associated correlated from CPT are presented in

Figure 9. The figure shows that the elastic modulus estimated from DMT tests are generally in good agreement with

that estimated from PLT tests and that the adopted values as shown in Table 3 are generally on the conservative side.

Figure 9: Comparison of Elastic Modulus using Correlated DMT and CPT results

5.3.4 Construction Methodology

Based on the results of the above tests, the construction methodology to be adopted for the dynamic replacement work

comprises:

i. Primary/penetration phase – this is carried out with a square penetrating pounder, weighing 26ton. A 20m

drop height is used. The aim of this concentrated pounding is to create a column, reaching the intended

depth with the specified diameter.

ii. Ironing/compaction phase – this is carried out using a octagonal compaction pounder weighing 24ton with

three drops from a reduced height of 10m.

The parameters established for the dynamic replacement sand columns are tabulated in Table 4.

Table 4: Design Parameters adopted for Dynamic Replacement Columns

Depth Soil Condition Expected

Diameter (m)

Friction angle,

φφφφ’ (deg)

Interpreted E

(MPa)

Remarks

0m – 2m Sand - 36 24.0 Compacted layer

2m – 3m Clay 3.3 36 21.0 Compacted column

3m – 4m Clay 2.5 36 21.0 Compacted column

4m – 5m Sand - 36 45.0 Compacted layer

5.4 CONSTRUCTION

The dynamic replacement has commenced since March 2008. The construction of the Dynamic Replacement work is

divided into three areas namely 30R, 30C and 30L. Each of the 30R and 30L covers an area of approximately 300m x

300m, while 30C covers an area of 600m x 300m.

At the time of preparing this paper, the installation work at 30R is already completed and work is proceeding in the 30C

area. Three Keller 120ton capacity rigs are currently working on site.

Post compaction testing comprises cone penetration testing, dilatometer testing and plate load test on selected columns

as in the verification trial. These testings form the main quality control of the ground improvement work. The regular

testing also allows for the calibration of the adopted compaction methodology throughout the improvement process, and

to make the necessary adjustments to ensure that the objectives of the ground improvement is satisfied.

Though the loadings from the stacker berms and coal pads have yet to be applied, the post construction testings have

shown that the ground treatment by dynamic replacement can meet the movement limits set out in the technical

specification. Figure 10 shows the completed improved ground with the column prints.

Figure 10: Completed Improved Ground by DR

6 CONCLUSION

The design and construction of the dynamic replacement works for the coal stockyard involved many challenges posed

by highly variable and difficult ground conditions.

The dynamic replacement works at the coal stockyard were in progress at the time of writing this paper. After

construction of the sand bench, geotechnical instruments were to be installed. The design and performance of the

improved ground will be closely checked and monitored using valuable data collected from the proposed

instrumentation schemes.

ACKNOWLEDGEMENT

The authors are grateful to the developer, Newcastle Coal Infrastructure Group, for their kind permission to publish this

paper. Coffey Geotechnics Pty Ltd is acknowledged in their capacity as technical reviewer of the dynamic replacement

works design.carried out by Keller Ground Engineering Pty Ltd.

REFERENCES

Priebe H.J. (1995), The Design of Vibro-Replacement, Ground Engineering, December 1995.

Schmertmann, J.H. (1978). Guidelines for cone penetration test: performance and design. US Department of

Tranportation, Federal Highway Administration, Offices of Research and Development, Washington (DC), Report

FHWA-TS-78-209 July 1978.

Jamiolkowski et al (1985). New developments in the field and laboratory testing of soils. Theme Lecture, 11th

International Conference on Soil Mechanics and Foundation Engineering, San Francisco, 1985.

Chan, K. F., Raj, D., Hoffman, G. and Stone, P. (2007), Designing stone columns to control horizontal and vertical

displacements. 10th Australia New Zealand Conference on Geomechanics, Brisbane, October 21-24.

International Symposium on Ground Improvement Technologies and Case Histories (ISGI09)

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GROUND IMPROVEMENT TECHNIQUES FOR EAST COAST EXPRESSWAY PHASE 2, MALAYSIA

Y.W. YEE * and C.G.CHUA* *Keller (M) Sdn. Bhd.,Kuala Lumpur, Malaysia [email protected], [email protected]

The East Coast Expressway (Phase 2) is 190km long and when completed, will connect Jabur Interchange to Kuala Terengganu. Ground treatment works were instituted where the highway passes through swampy ground and soft alluvial, in particular where high fill embankments were constructed. The objectives are to ensure embankment stability and restrict settlements to within acceptable limits. Several types of ground improvement techniques were implemented such as vertical drains and surcharging; vibro sand and stone columns and dynamic replacement. Typically, treatment depth ranged from 4 to 16m depth. This paper describes the design and construction of the ground improvement methods including quality control measures and insitu tests. The embankments were instrumented and monitored during construction to ensure performance was according to design requirements.

Keywords: embankment; soft ground; ground improvement; prefabricated vertical drain; vibro stone columns; vibro sand columns; dynamic replacement.

1.0 Introduction

The East Coast Expressway, Phase 2 (ECE 2) transverses 190 km long from Kuantan to Kuala Terengganu. It complements Phase I of East Coast Expressway (ECE 1) which connects Karak to Kuantan. When completed in 2011, it is expected to act as a catalyst to stimulate the economic growth of east coast of Peninsular Malaysia, particularly the state of Terengganu. The ECE 2 was designed as a four-lane dual carriageway with an average width of about 32m. The finished level was required to be higher than the flood level of 100 year return period as the east coast of Malaysia is often inundated by flood during the annual monsoon season. The structures of ECE 2 comprise of bridges, culverts, elevated structures, fill embankments and cut slopes. For the areas where fill embankments crosses swampy ground and soft alluvial sediments, various ground improvement techniques were employed to ensure embankment stability and restrict post-construction settlements to within acceptable limits.

The ECE 2 project was demarcated into 12 separate sub-packages under distinct work contracts. This paper presents the application of various ground improvement techniques, namely (i) Prefabricated Vertical Drain, (ii) Vibro Sand Column, (iii) Vibro Stone Column and (iv) Dynamic Replacement in 6 packages (2, 3, 9, 10, 11 &12). The design and construction of each ground improvement technique are described including relevant quality control procedures and insitu tests. The performance of various ground improvement techniques is explained from ground movement monitoring data.

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Figure 1. Typical cross section for Vibro Stone Column (left) and Dynamic Replacement Column (right).

2.0 Fill Embankments Treated Using Ground Improvement Technique 9

Typical cross sections of embankment fill are shown in Figure 1. Generally, each fill embankment has 32m width carriageway at the top and slopes with gradient 1(V):2 (H).

3.0 Subsoil Conditions

The treatment areas were generally located on swamps and soft alluvials. The geological map shows that the bedrock comprise of sandstone or granitic formation. Typically, soft ground comprises silty clay (cu = 10 to 15kPa) down to varying depths (6m to 16m). In general, water content is 50 - 60% and plasticity index 20 - 30%.

4.0 Performance Criteria

The roadways in ECE 2 are required to comply to performance criteria set by the Public Works Department (JKR) and Malaysian Highway Authorities (MHA). In general, the maximum allowable differential settlement is 100mm over a length of 100m (1 in 1000) along the centerline of embankment; and the overall embankment stability is required to achieve a factor of safety of 1.5.

5.0 Application of Ground Improvement Schemes 24

Various ground improvement techniques were used i.e. Prefabricated Vertical Drain (PVD), Vibro Sand Columns (VS), Vibro Stone Columns (VR) and Dynamic Replacement (DR) Columns. The selection of suitable technique was dependant on

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factors such as embankment height (weight), soil conditions (strength and depth) and availability of material. Cost factor was a prime consideration as well.

5.1 Design of Ground Treatment 3

5.1.1 Prefabricated Vertical Drain (PVD) 4

This technique was widely used because of its relatively low cost and quick installation. Application was mainly for low embankments up to 4 to 5m high. The embankments were built slowly using staged construction to allow the underlying soil to consolidate and gain strength. A surcharge of about 1m is normally placed to accelerate consolidation over a period of 3 to 6 months and limit long term settlement. Spacing between PVD points are typically 1 to 1.2m c/c triangular grid. In certain locations, embankments up to 8m were constructed with PVD in combination with VR (VR below the embankment slope and PVD across the carriageway). Basically, VR was designed to ensure stability and PVD to accelerate settlements. Such an application achieves greater economy but has a drawback of slower construction time. 5.1.2 Vibro Sand Columns (VS) 17

This technique was employed mainly where sand supply was freely available to stabilize embankment fill between 5m and 10m high. The VS design was based on Priebe’ (1995) method to work out the improvement factor in terms of settlement estimates and to derive composite parameters for slope stability analysis. The diameter of VS is 0.9m and typical spacing ranged between 1.6m c/c and 2.0m c/c. Surcharge period of 2 to 3 months are typical. In certain locations, combinations of VS and VR were used to stabilize embankment fill to maximum height of 13m, where VS was specified across the carriageway to reduce and accelerate settlement and VR was specified at embankment slope to ensure slope stability. 5.1.3 Vibro Stone Columns (VR) 29

Vibro Stone Columns were designed to support high embankment fill over very soft ground. The design methodology adopted Priebe’s (1995) method. The diameter of VR is 1.0m and typical spacing ranged between 1.8m c/c and 2.4m c/c, depending on embankment height. High embankments up to 13m have been designed for this project. Rest period for such high embankments are typically less than 1 month. 5.1.4 Dynamic Replacement Columns (DR) 36

Dynamic Replacement is basically an extension of the Dynamic Compaction method which is generally applied in granular soils. As soft fine grain soils cannot be compacted, the DR method is an improvisation to use the tamper to install granular columns in the ground. The depth of installation is limited to 6m (as explained in paragraph 6) and hence, is suitable for soft soils of shallow depths only. The columns are irregular shaped, typically 2.5m in diameter and spaced at 5.5m centres. Since the clear spacing between

columns is generally 3m apart (compared to 1m for PVD and VR), staged construction or a longer surcharging period of about 4 to 6 months is normally required.

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Figure 2. “Dry” Vibro Stone Column Rig Figure 3. Dynamic Replacement Rig

6.0 Execution

6.1 Prefabricated Vertical Drain (PVD)

The execution of Prefabricated Vertical Drain was carried out using conventional stitches mounted on light cranes. PVD was designed to be installed to medium stiff / to stiff layer.

6.2 Vibro Sand Columns (VS)

The execution for Vibro Sand Columns was similar to Vibro Stone Columns as described in literature (BS EN 14731: 2005, Yee & Raju (2007)). The challenges in the execution of Vibro Sand Columns were delivery of sand material to the tip of vibrator and achieving the required compaction effort. Site trials concluded that well-graded dry sand material having fines content not exceeding 10% was required to ensure properly compacted columns. Regulated air-pressure was incorporated during the construction process to avoid any heaving of adjacent vibro sand columns.

6.3 Vibro Stone Columns (VR)

Vibro Stone Columns (VR) were installed using bottom feed method (BS EN 14731:2005, Yee & Raju (2007)). Stones were fed at the top of vibrator and discharged directly to its tip through a special delivery tube attached to the vibrator. This method was pure displacement method where no soil is removed. A “dry” system (without water jetting) was specified by the authorities as an environmental protection requirement.

6.4 Dynamic Replacement Columns (DR)

Dynamic replacement columns were installed by inserting granular material into the ground from ground surface via repetitive pounding (BRE 458, (2003)). As illustrated in Figure 4, 15 tons to 25 tons tamper was repeatedly lifted between 10 to 15m by a specialised Dynamic Compaction crane and freely dropped onto the ground to form a

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crater which was then filled up by granular material. This process was repeated until sufficient amount of granular material was pushed into the ground or the ground surface has shown significant swelling which means that subsequent tamping would only push granular material sideways. From site observations, columns built using DR method were between 4 and 6m deep. Some aspects of construction that should be taken into account in the design are described herein. Firstly, installation of the column is by extreme displacement of the insitu soils, within an instantaneous time frame. Hence the surrounding soil will be displaced sideway, upwards (heave) and downwards. The soft soils displaced downwards imply that there is a layer of soft soils (about 1 to 1.5 m thick) below the toe of the column. This layer needs to be consolidated by surcharging. Figure 5a shows the soft layer formed below the toe of DR columns as detected by the post treatment CPT.

Figure 4. Schematic granular column formed by dynamic replacement method

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5a. Pre and Post treatment CPT indicating 5b. Post treatment CPT from centre of remoulded zone below DR column DR column to prove 2.5 m dia. column

7.0 Quality Assurance and Quality Control

7.1 Prefabricated Vertical Drain (PVD)

The QA/QC plan implemented on site comprised of 3 stages, namely pre-treatment, during execution and post-treatment. Pre-treatment testing (e.g. CPT and DPT) were carried out to establish the depths of soft soil. During the execution stage, the depth of installation was monitored independently and cross checked with material delivered to site on a daily basis to ensure sufficient depth as required by design was achieved. Finally, the embankment was monitored during construction to ensure that consolidation was occurring as per design requirement.

7.2 Vibro Sand Columns (VS)

The QA/QC plan for Vibro Sand Columns covers the construction methodology, material use, termination criteria and compaction effort to ensure desired diameter were achieved. Appropriate vibrator with sufficient centrifugal force (about 15 tons) was used. Material delivered to site was tested for specified grading at every 2,000 tons interval. The volume of bucket used to transfer sand into the ground was calibrated. The construction process was recorded in real time basis by a computer to ensure sufficient compaction of sand to build desired column diameter. Pre-treatment S.I. was used to calibrate the responding power consumption by the vibrator when a medium stiff to stiff layer was encountered for the first column installed. Subsequent installation would then be terminated at a depth where the agreed power usage was achieved. During compaction of column, each meter of column built was checked to achieve the required power usage in real time. At the completion of installation, CPTs were carried out at the center of column to ensure continuity and columns of adequate density (qc>5MPa). Staged construction was adopted for areas treated with VS. The embankment construction was monitored to ensure

Remoulded Zone

Post-treatment

Remoulded Zone

0.0

0.5

1.0

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8.0

0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0

Tip Resistance Qc [MPa]D

epth

[M

]

Pre-treatment

Post-treatment CPT 0m, 0.5m & 1m from the centre of column

0.0

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Dep

th [

M]

Post-treatment CPT 1.5m from the centre

of column

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stability and consolidation was occurring as per design requirement. Figure 6 shows the settlement versus time plot of a typical embankment on VS. In general, the compressibility of the VS treated soil is halved compared with soil treated with PVD.

-500

-450

-400

-350

-300

-250

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0

0 25 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400

Days

Sett

lem

ent

(mm

)

Monitoring Works for East Coast Expressway - LPT2

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

Em

ban

kmen

t H

eigh

ts (

m)

Figure 6. Typical settlement versus time plot on VS at East Coast Expressway

7.3 Vibro Stone Columns (VR)

The QA/QC plan implemented for VR was similar as per VS. Stone material used for VR was tested for specified grading and strengths. The embankment was constructed at specified rate of filling and was monitored during the construction to ensure the stability and consolidation was occurring as per design. Generally the compressibility of the treated area was half of that of the area treated using vertical drains, besides a much shorter consolidation time.

7.4 Dynamic Replacement Columns (DR)

Firstly, pre-treatment soil investigations (CPT and PMT) were carried out to establish that the depths of soft soil were less than 6m. Where the soils were deeper than 6m, alternative treatment methods were specified by the consultant (e.g. stone column). Secondly, site trials were carried out to ascertain that 2.5m diameter could be formed to 6m depth (see Figure 5b). During execution, the tamper drop height and number of blows were measured by an on board computer. Pre-programmed computer sequencing allowed consistent repeated drops without reliance on the operator’s reflexes to adjust lift heights and apply brakes. This enhances not only the quality of the product but safety on site.

Post-treatment CPT and PMT tests were carried out to ascertain column quality. The CPT was found to be more effective QA/QC tool than the PMT as it measures soil characteristics (strength and pore water pressure) continuously. The results are also found to be more repeatable and easier to interpret.

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The embankment was also monitored during construction to ensure that consolidation was occurring as per design requirement.

8.0 Conclusion

Ground improvement techniques applied as foundation for highway projects are widely accepted and are increasing in application in Malaysia. This paper presents the application of ground improvement techniques (i) Prefabricated Vertical Drain (ii) Vibro Sand Column (iii) Vibro Stone Column and (iiii) Dynamic Replacement in ECE 2. The concepts behind each technique are discussed, as well as their respective design methodology, execution, and QA/QC plan. Generally, ground improvement techniques were found to be adequate in supporting high embankments without instability and settlement issues. The selection of suitable method is dependant on factors such as embankment height, soil condition (strength and depth), availability of material and costs.

Acknowledgments

The authors wish to thank the Public Work Department and Malaysia Highway Authorities for allowing us to participate in this important project. We would also like to acknowledge the management and staff of the Main Contractors and Consultants (MTD Capital Berhad, GPQ-Bukit Puteri JV Sdn Bhd, Tidal Marine Sdn Bhd, TSR Bina Sdn Bhd, Cergas Murni Sdn Bhd, HSSI Integrated Sdn Bhd, Minconsult Sdn Bhd, Terratech Consultants Sdn Bhd and WNA Consultant Sdn Bhd) for their valuable contribution in the implementation of the ground improvement works. Colleagues in Keller who contributed immensely in the design and construction, in particular: Dr. V.R. Raju, Mr. Saw Hong Seik and Mr. Sreenivas are also appreciated.

References

Priebe, H.J., The Design of Vibro Replacement, Ground Engineering: p.31–37, (1995)

British Standard: BS EN 14731:2005, Execution of special geotechnical works – Ground treatment by deep vibration., 2005.

Building Research Establishment, Specifying dynamic compaction. BRE458. Garston, BRE Bookshop, 2003.

Yee, Y.W. and Raju, V.R., Ground Improvement Using Vibro Replacement (Vibro Stone Columns) – Historical Development, Advancements and Case Histories in Malaysia, 16th Southeast Asian Geotechnical Conference, Kuala Lumpur, Malaysia, 2007.

Reprint from:Advances in piling and ground treatmentfor foundations.Thomas Telford Ltd., London, 1983

Technical paper 11-53 E

Presented by

Keller Grundbau GmbHKaiserleistr. 44

D-63067 Offenbach

Tel. 069 / 80 51- 0Fax 069 / 80 51 -244E-mail [email protected]

Specialist GroundTreatmentby Vibratory andDynamic Methods

Dr. D.A. GreenwoodandDipl.-Ing. K. Kirsch

CHAPTER 3

Equipment List

EQUIPMENT LIST:

Dynamic compaction work requires heavy duty works for lifting and free dropping to the ground.

Therefore the cranes have to be designed specially of the boom section and the main winch to

be suitable for the job. The equipment list is shown in the table as below:

Equipment Number of unit Purpose of using

Heavy duty crane for DC 04 To lift up and free drop the heavy

tamping pounder

Pounder (08 – 20T) 05 For tamping on the ground

Wheel loader 04 Back fill the crater with structural fill mat

CPT Rig To carry out the cone penetration test

pre and post treatment

Hydraulic jack To carry out the plate load test for post

treated ground.

CHAPTER 4

Method Statement

Ministry of Construction Construction Corporation No. 1 8th & 9th Floor, Sailing Tower 111A Pasteur, Ben Nghe Ward, Dist. 1, Ho Chi Minh City Tel: 84.8.38222059 Fax: 84.8.38222172 Website: www.cc1.net.vn

Project: Long Son Petrochemical Plant Document Title: Method Statement DYNAMIC COMPACTION

Client: Long Son Petrochemical Co., Ltd Main contractor: Construction Corporation No.1 Specialist Sub-Contractor: Keller Foundations Vietnam Document Reference: Revision: 00 Date: 1st Mar, 2010

Name Organisation Signature

Prepared by Le Quang KFV

Checked by CG Chua KFV

Approved by YW Yee KFV

Long Son Petrochemical Complex Plant 2 of 6

Contents

1. Pre-treatment 2. Construction


Method statement Introduction

This Plan details the method statement to be carried during the ground treatment using the

Dynamic Compaction/Compaction technique for the improvement of soft ground at the Long Son

Petrochemical Plant, phase 1 of land development.

Dynamic Compaction Concept:

The ground treatment shall be carried out by repeated surface impacts using a heavy weight.

This leads to an increase in bearing capacity, a reduction of settlements under the proposed

loads. The method of compaction and plant type shall be determined with due regard to the depth

of treatment required, the proximity of existing structures and site operations. The method by

which the compaction shall be achieved shall be stated.

1. Pre treatment

The extent of individual work areas shall be based on the pre treatment soil investigation

carried out by Keller and on the drawing provided by the main contractor.

1.1 Working platform Working platforms shall be designed, prepared and maintained in a manner suitable for the

safe movement, ingress and egress, and working of the compaction plant. The main contractor will

provide the working platform at the level of below the foundation level 50cm. The main contractor

may cut or fill the natural ground level to the working platform level. In case of filling, material used

to provide working platforms shall be granular, substantially inert and free of clay and organic

material, and suitable for the ground conditions on which it is placed. The material used to provide

working platforms and which will form an integral part of the treatment shall be suitable for the

compaction process and permanent inclusion within the treated ground. A minimum thickness of

the working platform is 1m and is has to be maintained throughout the treatment process.

1.2 Setting out

Setting out shall be carried out from established grid lines maintained for the duration of the

dynamic compaction works. Immediately before treatment, each compaction point shall be clearly

marked with a wooden peg or similar marker. All compaction points shall be carefully set out to the

plan position shown on the contract layout drawings for the dynamic compaction works.


1.3 Trial compaction

A trial compaction will be carried out at the energy level specified to verify design assumptions

on ground behaviour. The progressive penetration of the free-fall weight or guided compaction foot

and heave of the surrounding ground shall be recorded and communicated to the Designer. The

Designer shall verify or modify the compaction design in accordance with the trial results

1.4 Imported fill

Imported material used for filling depressions formed by the compaction process shall be

complied to project specification of structure fill, the material grading curve is shown in figure 3.

The material required for back filling is supplied by the main contractor free of charge to a location

convenient to Keller’s earth moving equipment to carry out the dynamic compaction works

efficiently. The material shall be of approved quality and shall be delivered at a rate to suit Keller’s

progress.

1.5 Equipment

Tampers with weights of 8 to 20 tons are generally raised and dropped with a conventional

heavy crawler crane using a single cable with a free spool to allow the drop to be nearly free fall.

For heavier tampers, either conventional equipment is modified to reinforce certain components or

specially designed equipment is used to raise and drop the tamper. The tamper used during the

high energy phases generally should have a flat bottom and a contact pressure (tamper weight

divided by area of base) in the range of 40 to 75kPa. If the contact pressure is significantly higher,

the tamper could punch into the ground with little densification of the underlying soils. Smaller

contact pressures generally produce densification of the surficial soil only and should only be used

during the ironing phase.

The below figure shown the pounder before and after construction

Figure 1 : Dynamic compaction pounder


1.6 Site investigation:

Hard or cemented layers tend to distribute the impact load over a larger area, lessening the

energy transmitted to underlying layers. If located near the ground surface, the harder layer will

need to be loosened prior to tamping. A hard layer located immediately below the zone to be

improved has the beneficial effect of increasing the effectiveness of the treatment by reflecting

energy back into the loose materials.

2. Construction

The construction process is divided into several series of blows which are separated by the

backfilling works of the created crater. To start construction, the pounder has to be aligned in such

a manner that it is suspended centrally over the tamping location. The construction process is then

commenced by the first series of blows which is carried out directly on the working platform. The

amount of energy to apply at ground surface should be specified. If different energy levels are to

be specified for different areas, these areas should be clearly delineated on the drawings.

Approved fill material is then filled into the crater from a nearby stockpile or from the working

platform by means of a shovel loader or similar earth moving equipment. The backfilling shall only

be carried out if the crater is essentially dry. Once the backfilling is complete, the next series of

blows can commence. The process of delivering pounder blows in a series and of backfilling is

then repeated until the designed number of blows is completed.

After the primary and secondary energy has been applied, the amount of energy to apply

during the ironing pass to compact the surface of the deposit should be specified. If the surface is

to be compacted with conventional compaction equipment instead of ironing pass, this should also

be specified. The construction sequence and layout is shown in figure 2

Following completion of the dynamic compaction construction, where necessary, the treated

area will be levelled using a dozer, loader or similar. Any cutting works or removal of any material

shall be carried out by the main contractor. The treatment is then completed by compacting the

site surface using a vibratory roller or other suitable machinery to the required density.


X X X X

Y

Y

Y

Y

IRONING IRONING IRONINGPASS I PASS I

B B

CROSS SECTION B-B

DYNAMIC COMPACTION RANGE

PASS I - PRIMARY PASS USING 8-20TPOUNDER

DROP WEIGHT UP TO 20M

PASS II - SECONDARY PASS USING 8-20TPOUNDER

DROP WEIGHT UP TO 20M

IRONING - IRONING PASS WITH LOW ENERGY

D

Figure 2: Dynamic construction layout

SECTION 5

Tentative Work Sequence

Le Quang

Typewriter

Column depth <= 6m

Le Quang

Line

Le Quang

Line

Le Quang

Line

Le Quang

Line

Le Quang

Line

Schedule for DC works

Location Area (sp.m) Duration

(day)

Duration

(Week) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

2.0

Block 1 58,736 47.1 7.3

Block 2a 12,929 10.4 1.6

Block 2b 6,283 5.0 0.8

Block 3 7,084 5.7 0.9

Block 4a 84,525 67.8 10.4

Block 4b 19,612 15.7 2.4

Block 4c 44,242 35.5 5.5

Block 5 57,083 45.8 7.0

Block 6 32,970 26.5 4.1

Block 7 20,060 16.1 2.5

Block 8 48,930 39.3 6.0

Block 9a 15,102 12.1 1.9

Block 9b 25,697 20.6 3.2

Block 10 166,230 133.4 20.5

Testing

Block 11a 112,922 90.6 13.9

Overall schedule

Legend:

Crane No. Path Area comp. Dur.(w) Crane is planed for working 2 shifts per day

Rig1 178,101 22 Stone consumption is estimated about 2000 m3/ day

Rig2 178,101 22

Rig3 178,101 22

Rig4 178,101 22

SECTION 6

QA/QC Plan

Ministry of Construction Construction Corporation No. 1 8th & 9th Floor, Sailing Tower 111A Pasteur, Ben Nghe Ward, Dist. 1, Ho Chi Minh City Tel: 84.8.38222059 Fax: 84.8.38222172 Website: www.cc1.net.vn

Project: Long Son Petrochemical Plant Document Title: QA/QC Plan DYNAMIC COMPACTION

Client: Long Son Petrochemical Co., Ltd Main contractor: Construction Corporation No.1 Specialist Sub-Contractor: Keller Foundations Vietnam Document Reference: Revision: 00 Date: 1st Mar, 2010

Name Organisation Signature

Prepared by Le Quang KFV

Checked by CG Chua KFV

Approved by YW Yee KFV


Contents

Section 1

1. Quality Control

2. Documentation

3. Non Conformances

4. Attachments

Section 2 Inspection and Test Plan


1. Quality control

1.1 Pre treatment test

A ground investigation will be necessary before the actual installation works. Geotechnical

parameters for the site should be evaluated in order to confirm the design. The depth to, and any

variation in, ground water level should be identified for all dynamic compaction works. The extent

of the investigation will depend on a number of factors, including treatment area, the nature and

variability of the soils, the depth of filled ground, the depth and extent to which the ground will be

loaded and the type and function of the structure to be supported. Some of all of the following

should follow the desk study and walk-over survey:-

a) Boreholes

As provided in the Tender documents.

b) In-situ tests

As well as assessing the pre-treatment ground conditions for design purposes, it will often

be necessary to quantify geotechnical parameters that the dynamic compaction treatment

seeks to improve. A measure of the degree of improvement achieved and the depth to

which it has been achieved can then be made.

Probing or penetration testing such as static cone penetration tests (CPT) and dynamic

penetration tests (DPT) may be used to categorise a treatment area. Penetration testing

before and after the treatment will measure the change in penetration resistance in the

soils. Results should be correlated with borehole data. Measurement during SPT or CPT

testing can provide information on:

- The soil types encountered,

- Preliminary estimates of the properties of the soil, including the density (in

granular soils), undrained shear strength (in clay soils), the effective angle of

shearing resistance and compressibility.

DPT is lightweight, easy and economical to operate and relatively robust for use in

miscellaneous fills. DPT provides rapid assessment of variability but for more detailed information

other testing is required. Where cohesive soils are present that use of a piezocone (CPTu), a CPT

in which pore water pressures can be measured, may be appropriate.

1.2 Granular material

Granular material for backfilling the dynamic compaction crater shall be clean, hard, durable

and inert and naturally occurring materials. The material shall have the grading within the specified


limits given in Table 2 below. This material has to be complied with approved specification for

structural fill material. The fill material grading curve is shown in figure 3

Description of Material British standard sieve aperture

size % Passing (By weight)

Granular Material

50mm 100

9.5mm 30-65

4.75mm 25-55

2mm 15-40

0.425mm 8-20

0.074 < 8

Table 2: Structural fill material specification

0

10

20

30

40

50

60

70

80

90

100

0.01 0.1 1 10 100

Per

cen

tag

e p

assi

ng

by

wei

gh

t

Sieve Size ( mm )

Upper limit Lower limit

Figure 3: Grading curve of structural fill material

1.3 Site control

Prior to commencing the actual installation works, shop drawing(s) are prepared for each

location to be treated. These drawings shall be used to set out the treatment grid and will also

show the extent of the treatment.


Major reference points shall be provided by the main contractor to enable the treatment grid to

be set out. The following information will be recorded during the treatment:

1. Ground levels prior to treatment (taken by surveyors).

2. Identification unique to each pounder location

3. Number of blows per location

4. Volume of backfilled material

5. Ground levels after treatment (where practical)

Records for 2, 3 and 4 will be recorded on an as-built drawing.

1.4 Daily installation report

The daily report is the prime quality control document; it records the compaction parameters of

each probe point as in 2.1 above. In addition to analysing the information at the end of each day

the record sheets are correlated to the layout drawing and marked as complete. In this way no

probe points can be missed and the human error factor is eliminated. Example sheets are

attached.

1.5 Performance testing

Performance testing is carried out to verify the degree to which ground improvement has been

achieved and confirm that this meets the specified objectives. The behaviour of variable fills may

be complex. Testing a portion of the treated ground that reflects the anticipated use in scale and

geometry is the most effective way of proving the performance of the treatment.

1.5.1 Trial test

Testing and verification of the performance of the dynamically consolidated platform is carried

out using plate load tests which are carried out as outlined below.

A suitable level test area is chosen at random with test alternated to be located centrally on or

equidistant between compaction print positions. An area of approximately 1.2m in diameter is

cleaned of loose or disturbed material and levelled using a fine sand/cement mix. The steel

bearing plates that will transfer the applied load are placed onto the prepared area taking care to

keep them level. A hydraulic jack of suitable capacity (20 to 50ton) is placed onto the bearing

plates along with any spacer plates as required.

The reaction for the test is provided by the crane which is tracked over the test such that the jack

can come into contact with the centre of the carriage beam. After placing the crane in position the

dial gauges can be set up.


Two steel beams/box sections each of approximately 5m in length are set up parallel to the crane

tracks and close to the bearing plates, the ends of the beam should be located firmly above the

existing ground so that as the test is loaded it will have not effect of the beams. Four magnetic dial

gauge holder are attached to the beams along with dial gauges. Two sets of gauges should each

be located onto the bearing plates placed diagonally opposite each other taking care that they

have sufficient travel in the down direction.

After applying a bedding load of the order of 10% of the working load the test load is applied in two

cycles, the first to working load and the second to twice working load (WL = 110kpa or 87KN).

Loads are applied in increments of the order of 20% of working load and kept at each interval for

at least 1 minute before reading the dial gauges. On the release cycle two readings are taken at

interim loads and after full release of the jack pressure.

At the first 100% WL , 200% WL, and after both release cycles readings are taken after 1minute, 5

minute and 10 minutes, with the pressure adjusted if necessary in the even of loss of pressure due

to settlement or other reasons. The release valve is kept open or the full duration of when zero

load readings are taken to ensure unrestricted rebound of the plates.

Load versus deflections are recorded and plotted on the “Plate Load Test Report” sheet.

1.5.2 In situ penetration test

In-situ penetration tests may be used where changes in properties of the soil due to dynamic

compaction can be measured and directly compared with pre-treatment test data. These

techniques are also used to assess the depth to which effective compaction has been achieved.

Two test methods are recommended: dynamic penetration and cone penetration tests, but there

are also less frequently used techniques such as the standard penetration test.

a) The dynamic penetration (DPT) determines the in-situ resistance to the penetration of a 90o

cone driven dynamically in a standard manner (BS 1377: Part 9). Expressing results in terms of

dynamic point resistance provides a means of standardising measurements for different sites. The

equipment is relatively mobile and robust, does not require a pre-drilled borehole and can provide

almost continuous measurements with depth. It can be used economically to detect variations in

soil consistency with depth over a wide treatment area, e.g. to locate soft layers and strong layers.

b) Cone penetration tests (CPT) determine the resistance to the continuous penetration at a slow

uniform rate of a series of push rods with a cone at the base (BS 1377: Part 9: Test Method 3.1).

In addition to penetration resistance of the cone and the local friction resistance on a friction


resistance on a friction sleeve, pore water pressure in the vicinity of the cone and sleeve may be

measured. Results are interpreted by the use of empirical correlations. While less robust and most

costly than DPT, this test method can provide valuable guidance about the nature of the soil being

penetrated and more reliable information concerning soil properties.

2. Documentation

The following documents shall be completed during the dynamic compaction works:

Tool Box Talk (as required) Pre-Treatment SI Report DC Penetration Test (03 location) DC Production Sheet (Weekly) DC Daily Report (Daily) Post-Treatment Verification Report Plate Load Test Report Non Conformance Report

3. Non conformances

Should a non conformance be identified a Keller non conformance form shall be completed (see

attached). A register of non conformances shall be established in order to track close out. When a

non conformance is identified corrective action should be recommended and a close out date

established. Only then can the non conformance report be closed out.

4. Attachment


D. C. PRODUCTION SHEET


DYNAMIC COMPACTION

DAILY REPORT


D.C. PENETRATION TEST


Keller Ground Engineering Pty LtdABN: 68 008 673 167

NON-CONFORMANCE REPORT (N.C.R.)

Contract Name: N.C.R. NO:Keller Contract No: / State* Number

State* Number

Non-Conformance DetailLocation of Non-Conformance:

Description of Non-Conformance:

N.C.R. Issued by: / /(Date)

Remedial Action (Short Term)Action by: Keller Keller's Subcontractor Client Client Design Engineer Other

Type of Action: Use as is Down-rate Scrap Replace Repair

Details of Remedial Action:

Proposed by: / /Keller/Other (Date)

Approved by: / /Keller/Other (Date)

Corrective & Preventative Action (Long Term)

Does an underlying problem exist? No Corrective Action not required

Yes Corrective Action required, detail action required:_______________________________

Reviewed by: / /(Date)

N.C.R. Close-OutCompletion Date:

Comments:

Verified by: / /Keller (Date)

Verified by / /Keller Client if required (Date)

Distribution: Keller Client Keller P.M.: Other:

* Insert number to represent geographicsl location2=New South Wales 3=Victoria 4=Queensland 5=South Australia 6=Western Australia 7=Tasmania 8=Northern Territory 9=ACT

10=Off-shore (Papua, Fiji, New Zealand, etc) Form SF013

(Name) Keller (Signature) (Position)







Section 2

Inspection and Test Plan

KELLER (M) Sdn Bhd PROJECT QUALITY PLAN INSPECTION AND TEST PLAN ITP DOC No.: CONTRACT: CONTRACT No.: DETAILS: DC Date Installed: DRAWING Nos.: Item No.

Inspection Activity

Method Acceptance Criteria

Frequency Records Responsibility Keller Client

Sign off

Keller

Remarks


1.0 Dynamic Compaction

1.1 Setting Out Layout Drawing/Grid Lines

Set out peg or rock pile

Each Column As Built Drawing

DV M Pounder location identified by peg or rock pile.

1.2 Check Pounder location 150mm in plan from centre peg

Within 150mm Every location Daily report DV M

1.3 Carry out trial penetration to achieve number of blows

Monitor number of blows, depth of imprint and height of ground heave

Produce graph of blows versus depth of treatment

Each fill depth area

Trial Penetration Report

VDR M Graph produced used to establish the required minimum number of blows for a given area or particular depth of treatment.

1.4 Carry out pounder treatment Record blows and depth of print

Minimum number of blows

Every location Daily report DV

2.0 Pre-Treatment Testing

KELLER (M) Sdn Bhd PROJECT QUALITY PLAN INSPECTION AND TEST PLAN ITP DOC No.: CONTRACT: CONTRACT No.: DETAILS: DC Date Installed: DRAWING Nos.: Item No.

Inspection Activity

Method Acceptance Criteria

Frequency Records Responsibility Keller Client

Sign off

Keller

Remarks


2.1 Carry out Dynamic Penetration Tests (DPT)

DPT -

SI Report DV M Locations chosen at random by Keller.

2.2 Carry out Cone Penetration Tests (CPT)

CPT - SI report DV M Locations chosen at random by Keller.

3.0 Post-Treatment Testing

3.1 Carry out plate load tests Plate load test method

Plate Load Test Report

DV M Locations chosen at random by Keller.

3.2 Carry out Dynamic Penetration Tests (DPT)

DPT Verification Report


3.3 Carry out Cone Penetration Tests (CPT)

CPT Verification report


( H ) Hold, ( M ) Monitor, ( W ) Witness, ( D ) Dimension, ( V ) Visual, ( R ) Review Doc., ( S ) Send Doc. * The frequency of tests is subject to the soil variability at site Sign Off Client:__________________ Date:_________ Sign Off Keller:__________________ Date:________

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