STEEL SHEET PILING DESIGN MANUAL

State-of-the-art sheet piling foundation solutions and their applications

Dr. Pierre-Nicolas Werner Head of Business Development, ArcelorMittal Commercial RPS IQPC Piling and Deep Foundations Africa – Johannesburg 16th August 2011

Agenda • Introduction to ArcelorMittal’s state-of-the-art range of foundation solutions • Solutions for transport & urban infrastructure projects – Case study ‘Unterinntalbahn’ (Brenner) railway line, Austria

• Solutions for harbour construction – Case study Jade Weser Port, Germany

• Straight web sheet pile solutions – Case study Solis hydroelectric dam, Switzerland

• Recent innovation – durability example • ArcelorMittal – your worldwide one-stop provider of foundation solutions

th Johannesburg, 16 August 2011

Piling and Deep Foundations Africa 2011

1

A bit of history… • First rolled steel sheet pile in USA: Lackawana type, 1908. • Since 1911, ARBED / ARCELOR / ArcelorMittal have improved sheet pile sections



2

A bit of history…



3

Types of steel sheet piles – 1

U - section

Z - section

Combined wall th Johannesburg, 16 August 2011


4

Types of steel sheet piles – 2 Max. Wx (cm3/m) approximately: • U-type:

3 200

• Z-type:

5 000

• HZM/AZ: • Pipe/AZ:

Section modulus Wx per type of sheet pile solution

46 500

50 000

45 000

45 000

46500

45000

4800

4000

40 000

Applications: • temporary, small excavations / retaining structures: Wx < 2 500 • marine structures (<12.0m dredge level) / deep excavations: Wx < 5 000

3

) 35 000 /m30 000 m25 000 (c x W20 000 15 000 10 000 5 000

5015

0

• large quay walls / deep cofferdams: Wx > 5 000 th Johannesburg, 16 August 2011

3200


U-typ e

Z-typ e

HZM /AZ Pipe /AZ

5

Hot rolled Z and U type steel sheet piles (2011)

AZ 13

AZ 18

AZ 26

AZ 48

Z type AZ 13-770

PU 12

U type

GU 7N

AU 16


AZ 18-700

PU 18

PU 22

GU 13-500

AU 20

AZ 26-700

PU 28

AZ 38-700N

PU 32

GU 16-400

AU 25


6

Old range of HZ / AZ (since 1990’s)

23

17 0 5 0 1

462

HZ575

HZ775

HZ975

HZ1050

• Combined wall system with 4 sections, 4 thicknesses (A, B, C, D): • Elastic section modulus Wel,y

2 870

• Moment of inertia Iy-y

up to 1 731 300


– 32 045


(cm3/m) (cm

4/m)

7

Steel grades for hot rolled steel sheet piles EN 10248

ASTM

fyk [MPa]

JIS

fyk [ksi]

fyk [MPa]

S 240 GP

240

S 270 GP

270

A 328

39

270

S 320 GP S 355 GP

320 355

A 572 Gr. 50

50

345

S 390 GP

390

A 572 Gr. 55

55

380

S 430 GP

430

A 572 Gr. 60

60

415

S 460 A P *

460

A 572 Gr. 65

65

450

fyk [MPa]

SY 295

295

SY 390

390

• Addition of copper 0.35%, 0.50% • ASTM A 690: high strength low alloy steel for use in marine environments (Gr. 50 and higher available) th Johannesburg, 16 August 2011


8







9

CAS E S TUDY

Unterinntalbahn (Brenner) project – Austria

• Carried out by th Johannesburg, 16 August 2011


10

Challenges • All retaining walls initially designed in concrete – sheet pile combined walls not previously used in Austria as temporary structure • Proximity to existing (running) railway line and roads, and to buildings • Proximity to river Inn and risk of flooding • Existing groundwater level • Multiple crossing over/under river, roads and existing railway • Multiple construction methods – Conventional tunneling (including under compressed air) – Cut-and-cover method with underwater concreting – Shield tunneling method • Many different cross sections along the 40km track



11

Driving tests – water jetting tubes

15

25 bar Pump



Water Tank

12

Driving tests HZ king piles • First temporary use of HZ-AZ combined wall system in Austria



13

Driving tests AZ sheet piles



14

Declutching detection: DIXERAN

Detail A

Protection cap Control box

If necessary to verify the integrity of the wall, i.e.: • hard driving / obstacles • cut-off walls (environmental jobs) ‘Dixeran’: detector to verify the shearing of a pin

Detail A th Johannesburg, 16 August 2011


15

Cut & cover building phases – 1



16

Driving of sheet piles



17

Example of driving plan HZ-AZ combined walls and PU anchor walls



18

Driving of sheet piles HZ-AZ combined walls and PU anchor walls



19

Driving of sheet piles Introduction of sealant – use of driving template



20

Driving of sheet piles PU anchor wall



21

Dredging works



22




23

Underwater works supervised by divers



24

Anchoring & concreting



25

Dewatering of trenches



26




27

Finishing concreting works after dewatering



28

Tunnel construction / introduction of tunneling machine in finished dry trench



29

Removal of sheet piles for re-use or sale



30

Temporary sheet pile retaining wall for safety shaft



31

Proximity to roads and existing railway



32

Other major recent transport infrastructure projects

Widening of M1 & M25 motorways, UK

Vienna Metro, Austria High Speed Line, Netherlands th Johannesburg, 16 August 2011


33

Examples of sheet piles in permanent use for transport / urban infrastructure

Congonhas underpass Sao Paulo Airport, Brazil

Project location th Johannesburg, 16 August

2011


34

Examples of sheet piles in permanent use for transport / urban infrastructure Flood defences

Bridge abutments

Underground th Johannesburg, 16 August 2011

car parks Piling and Deep Foundations Africa 2011

35







36

New range of HZ-M

Nb of sections

h (mm)

t (mm)

s (mm)

w (mm)

HZ 880 M

A, B, C

831

19 - 23

13 - 15

458 - 460

HZ 1080 M

A, B, C, D

1075

20 - 30

16 - 19

454 - 457

HZ 1180 M

A, B, C, D

1075 - 1087

31 - 37

20 - 22

458 - 460

w

w/4

r

tmax

t h h1

h h1

y

s

y

HZ 880 M t = 19, 21, 23 mm th Johannesburg, 16 August 2011

tmax

y

y

h

y

y

s

s

HZ 1080 M

HZ 1180 M

t = 20, 23, 26, 30 mm Piling and Deep Foundations Africa 2011

t = 31, 33, 35, 37 mm 37

New HZ-M production facility Concept: milling instead of rolling Two separate milling tools are shaping the groove into the HZ-M flange to enable the threading of connectors for AZ-infill elements.



38

Comparison HZ-M / HZ Standard AZ infill sheets: AZ13, AZ13-770, AZ18, AZ18-700, AZ26, AZ26-700 Iy

Wel,y *

G100%

(cm4/m)

(cm3/m)

(kg/m2)

HZ 575 A-12/AZ13 HZ 1050-C23

96 470 1 731 300

2 870 32 045

178 705

HZ 880M A-12/AZ 13-770 HZ 1180M D-C23

215 290 2 579 400

4 815 46 500

200 992

Combination 12



+ 45%

Combination C23

39

Performance of new HZ-M range

HZ-M HZ…. 12 & 24

Infill sheet pile: AZ18-700

13 265



18 895

40

CAS E S TUDY

Deep Sea Terminal JadeWeserPort

Germany: location of logistic n1 in Europe - Present capacities are not sufficient to comply with increase of cargo handling in near fut ure Wilhelmshaven: existing navy harbour - Good transport connection with rails and highway connection - Natural water depth 18 m - Economically underdeveloped region - Close to CT Bremerhaven and Port of Hamburg th Johannesburg, 16 August 2011


41

Deep Sea Terminal JadeWeserPort General layout 1.725 km New access channel

Facilities  Berths:

4

Container

cranes:

Van  Carrier: Stacker:  

16

120 ha

68 8

170 ha

Train handling cranes: 5



42

Quay wall cross section

+7,50 m 0 8 , 0 3

-23,30



43

Construction of the quay wall with ArcelorMittal sections HZ1080M A–24 / AZ 13 12/12 y

y

Infill sheets AZ 13-12/12

AU 20

Main piles HZ 975 HZ 1080M

Anchor piles HTM 600/136

Fender piles D=1219 mm t=25 mm Steel piles D=813 mm t=17.5 mm



44

HZ-M Box piles – length up to 46 m

Max. rolling length: 33 m Splicing of HZM th Johannesburg, 16 August

2011


45

Fabrication of box piles & shaping



46

Challenge: fabrication / logistics / storage

• • • • • • •

HZ 1080 M – 24 L = 24 – 48 m G = 18 up to 46 mt total 830 box-piles 25 - 30 pieces per week  > 1000 mt / week delivery plan



47

Positioning of king piles in template



48

Driving of main king piles Jack-up platform and supply barge



49

Driving of battered anchor piles, double acting hydraulic hammer guided on a leader



50

Installation of the infill sheets

AZ 13-12/12, with min. thickness of 12.0 mm Vibratory hammer th Johannesburg, 16 August 2011


51

Anchor pile connection to the front wall

Hinged connection th Johannesburg, 16 August 2011


52

Anchors in corner before start of filling works



53

Driving tests for HZM king piles

10 load bearing tests: compression



5454

Tension tests for HTM anchor piles Inclinometers Strain gauges



5555

Harbour Area before starting



56

June 2008

27. Mai 2009



57

November 2008

27. Mai 2009



58

January 2009

27. Mai 2009



59

August 2009



60

December 2009



61

March 2011

www.jadeweserport.de



62

Illustration of completed terminal



63







64

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

Thickness web

Interlock strength

fyk min. yield strength

[mm]

[kN/m]

[MPa]

AS 500

300 mm  L  500 mm testing: EN10248-1


9.5

3000

355

11.0

3500

355

12.0 12.5

5000 5500

355 355

12.7

5500

355

•

gravity structure

•

deep wharfs / quays / breakwaters / cofferdams

•

structures founded on bedrock

•

no anchors


65

Types of cells

Circular cells

junction pile

Diaphragm cells th Johannesburg, 16 August 2011


66

CAS E S TUDY

Solis hydroelectric dam, Switzerland



67

Looking for a solution – 1



68

Looking for a solution – 2



69

Original design – complex double-walled sheet pile cofferdam with 6 levels of struts



70

After optimisation…



71

Section along cofferdam

Max. sheet pile length 30.5m Lake bed

Gravel backfill

Silty lake sediments  ~ 20-24 g ~ 19-21 kN/m3 °

Rock line

Splicing to add 6m of length + grouting

• 528 sheet piles (AS500-9.5 and AS500-12) with a total tonnage of 859 kt were delivered. th Johannesburg, 16 August 2011


72

A logistical challenge

Spreader beam with attachment for handling of long piles



73

Putting into place the circular template



74

Installation

junction pile



75

After backfilling and drainage



76

Next step – reuse of sheet piles and conversion from temporary to permanent cofferdam!



77

Seo-Hae Grand Bridge, South Korea



78

Tug-boat quay in Paraíso, Panama Canal

AS 500-12.0 20 circular cells  = 15.0 m, L = 18.5 – 20.0 m  3000 t



79

Circular Cell Structure E-METHANEX Berth, Damietta, Egypt



80

Diaphragm Cell Structure Essar Quay wall, Hazira, India



81







82

Durability of steel structures • corrosion in undisturbed natural soils is negligible (exception peat, …) • in common fresh water, corrosion is low • in sea water, corrosion has to be considered (splash zone, low water) • reference for loss of steel thickness: Table 4.1 & 4.2, EN 1993-5 (2007) design life (years) 5 undisturbed natural soils (sand, clay, …)

25

50

75

100

0.00

0.30

0.60

0.90

1.20

common fresh water: waterline

0.15

0.55

0.90

1.15

1.40

sea water : permanent immersion & intertidal

0.25

0.90

1.75

2.60

3.50

sea water : splash & low water zone

0.55

1.90

3.75

5.60

7.50



83

Introducing AM LoCor™



84

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85

ArcelorMittal Sheet Piling  Foundation Solutions • extensive engineering pool & technical assistance team for external interventions • provide regular in-house training for internal and external technical sales force • elaborate adequate design software & update technical documentation (PHB,…) • provide educational training programs for engineers at universities, consultants and contractors • leading participation for EC standards, NASSPA, Chinese Standard Institute, Brazilian Standard Institute for the construction industry



86

ArcelorMittal Sheet Piling  Foundation Solutions • develop sheet pile technology with R&D as well as with external institutes • driving tests before validation of new sections or to confirm project choice and jobsite assistance if required • close cooperation with driving equipment manufacturers • provide accessories as for example tie-rods, coating, sealants, driving caps, steel fabrication works and offer them as a package together with the sheet piles, tubular piles and bearing piles • use stocks (new and second-hand), offer rental contracts and buy-back options • Supply Chain Management: just-in-time deliveries th Johannesburg, 16 August 2011


87

Thank you for your attention http://www.arcelormittal.com/sheetpiling Piling and Deep Foundations Africa 2011 http://www.arcelormittal.com/projects


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STEEL SHEET PILING DESIGN MANUAL

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