Application of Vibro Techniques for Infrastructure Projects in India

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1 Application of Vibro Techniques for Infrastructure Projects in India Rainer Wegner Contract Manager, Keller Grundbau GmbH, Germany Dr. V.R. Raju Director, Keller Ground Engineering India Pvt Ltd, India A. Vetriselvan Engineering Manager, Keller Ground Engineering India Pvt Ltd, India Presented by Keller Grundbau GmbH Kaiserleistr. 44 D Offenbach Tel Fax Technical paper 10-61E

2 APPLICATION OF VIBRO TECHNIQUES FOR INFRASTRUCTURE PROJECTS IN INDIA Rainer Wegner Contract Manager, Keller Grundbau GmbH, Germany. Dr. V. R. Raju Director, Keller Ground Engineering India Pvt Ltd, India. A.Vetriselvan Engineering Manager, Keller Ground Engineering India Pvt Ltd, India. Abstract Ground improvement is often required to stabilise weak soils for the construction of major infrastructure projects. Deep vibratory techniques have found acceptance and application worldwide as technically sound and cost effective ground improvement methods. This paper describes the application of Vibro compaction for the construction of breakwaters to a total length of 5 km for the Seabird Naval Base at Karwar, Karnataka and the application of Vibro Replacement for the construction of two LNG tanks of 84m dia at the Shell LNG terminal at Hazira, Gujarat. The paper explains the basic principles of the two techniques, the methodology and quality control measures adopted. 1. INTRODUCTION Large civil engineering projects are being executed in India in order to enhance the infrastructure of the country. Infrastructure facilities have to be often built at sites where the soil conditions are not ideal. The soils may vary from loose sands to soft clay deposits requiring treatment to improve the shear strength and to reduce the liquefaction potential in the case that the selected area is prone to seismic activity. Rigid foundations such as piling present a solution but these are often expensive. In such circumstances, ground improvement using Vibro techniques offers a proven and economical solution. This paper explains the application of Vibro techniques in two different soil conditions: 1. Vibro compaction methodology and its achieved results in the construction of a breakwater at the Seabird naval base at Karwar and 2. Vibro Replacement (Vibro Stone Columns) process and its application in the construction of two LNG tanks of 84 m diameter at the Shell LNG Terminal at Hazira. 1

3 R. Wegner Dr. V. R. Raju A.Vetriselvan 2. VIBRO COMPACTION Vibro compaction is a technique used to densify loose filled or formed granular soils having fines contents generally in the range of upto 10% to 15% using depth vibrators. The vibrations are produced by rotating a heavy eccentric weight with the help of an electrical motor within the vibrator. The vibratory energy is used to rearrange the granular particle in a denser state. The vibrator with extension tubes is allowed to penetrate into the soil with the help of vibratory force and high pressure water jets. Once the vibrator reaches the required depth, the water jets are stopped/reduced and the vibrator is pulled back in short steps, in each step the vibrator is held for a predetermined time interval. During this time, inter granular forces between the particles are reduced which helps in rearranging the particles in a denser state. The process is repeated up to required level to form a soil mass having improved shear strength and compressibility parameters Break Water at Karwar As part of the construction of a naval base, breakwaters having a total length of about 5 km (3.2 km on the southern and 1.8 km on the northern side) are being constructed. The width of the breakwater at its base is 120 m. The soft clay present below the seabed at the proposed breakwater location was dredged to a depth of 6 m and backfilled with sand hydraulically. The sand available in near by borrow pits was used as fill material. Figure1 shows a cross section of the breakwater and the subsoil showing the sand layer to be compacted. In order to avoid excessive settlements and to reduce liquefaction potential, the top portion of the 3.5 m to 4 m hydraulically filled sand layer was required to be compacted. The requirement was an increase in cone penetration resistance at depths of 2 m & 3 m below seabed level by 1.5 MPa and 2.0 MPa respectively from the original precompacted value. +10 m ±0 m Water level Break water 1m layer of coarse sand 10 m 14 m Compacted sand fill 120 m Fine sand Sea Bed (clay, soft silt) Figure 1: Cross section of breakwater Keller carried out the densification of the sand layer over an area of about 140,000 sq.m using the Vibro Compaction technique. Based on a trial, a spacing of 3 m square grid was chosen and the compaction process was monitored using Keller s M4 automatic recorders. The observed settlement ranged between 0.2 m and 0.3 m arising from the compaction of 4 m of sandfill. The compaction works were completed over a period of about 10 months effective working time (excluding bad weather periods) between January 2001 and August Setup of Equipment: Four vibrators (quatro setup) attached with a follower tube of length 15 m each were suspended from a steel frame. The steel frame setup with vibrators was suspended from a 150 T crane on a barge. This system facilitates the compaction of 3.5 m to 4.0 m of sandfill in about 10 m of water. A schematic arrangement of the barge and equipment is shown in Figure 2. 2

4 Application of Vibro Techniques for Infrastructure Projects in India Dredged trench and fill Figure 2: View of offshore Quatro Vibro setup 2.3. Working Sequence: First the barge was towed by a tug to the compaction area and anchored either parallel or perpendicular to the centre line of the breakwater. The barge was positioned with the help of winches and the vibrator probes were positioned using a global positioning system (GPS) which was mounted on the centre of the quatro setup. The vibrators suspended from the crane were slowly lowered into the water until they touch the seabed, then the vibrators were further penetrated into the seabed to a depth of about 4 m. After reaching the required depth the vibrator was held in position with its motor running for a period of 30 to 40 seconds. It was then lifted by 0.5 m and this process was repeated until the vibrator reached the seabed. This process was repeated for all points to compact the entire plan area of the breakwater uniformly Testing CPT tests were carried out following a period of 7 days after compaction at every 50 m length along the breakwater. The tests were conducted at the predetermined locations and were typically at the centroid of the four compaction probes or at the mid point between two compaction probes. Typical pre and post compaction CPT test results are shown in Figure 3. The post compaction CPT values were often found to be 2 to 3 times more than the pre compaction CPT Values. Pre CPT Post CPT Cone Resistance (MPa) Figure 3: Typical CPT results Depth (m)

5 R. Wegner Dr. V. R. Raju A.Vetriselvan 3. VIBRO REPLACEMENT Vibro replacement is a technique used to improve cohesive soils such as silts and clays and granular soils with high fines contents (>15 to 20%). In this method, columns made up of stone are installed in the soft/loose soil using the depth vibrator. The vibrator is used to first create a hole in the ground, which is then filled with coarse granular fill (stones) during withdrawal of the vibrator. The stones are then laterally displaced into the soil following repenetration of the vibrator. In this manner a column made up of well compacted stones with diameters typically ranging between 800 mm and 1100 mm can be installed in the ground. Two methods of installation namely the wet and dry methods are available for the installation of the columns. In the wet method, water jets are used to create the hole and assist in penetration. In the dry method the hole is created by the vibratory energy and a pull down force LNG Terminal at Hazira Shell India is constructing two LNG storage tanks at the Hazira LNG Terminal. The diameter of the tanks is 84 m with a filling level of approx 35 m (see Figure 4). The sub soil at the site consists of loose to medium silty sand to a depth of 10m. Below this, alternating layers of sand and silty clay are present to a depth of 16 m. The top 3 m were recently reclaimed material. The average fines content in the sand over the depth was in the range of 15% to 25%. Medium dense sand with SPT N > 30 was encountered below 16 m. The poor subsoil conditions and the intensity of earthquakes in the region resulted in the requirement for soil improvement prior to construction of the tanks. T1001 LNG Storage Tanks 160,000 m³ T1002 Inner Shell Double-Wall Tanks Outer Shell 16 m Pipe route Stone columns Pumps Pumps Zone of improvement Pipe Rack 84 m dia. Tank T1001 T m dia. Figure 4: LNG Tank founded on stone columns 4

6 Application of Vibro Techniques for Infrastructure Projects in India 3.2. Treatment The 34 m high LNG tank imposes a static design load of 230 kpa. In addition a maximum peak ground acceleration of 0.25 g is to be expected during a possible earthquake event. Ground treatment was therefore required to a) Increase the density of the soil and there by reduce the settlements of the tank under the static load to within 120 mm. b) Reduce the liquefaction potential in the sand layer by strengthening the subsoil and also by providing effective drainage to prevent excess pore water pressure. Vibro stone columns (Vibro Replacement) was selected to achieve the above objectives. The coarse permeable material of the column allows rapid dissipation of excess pore water pressure. The columns made up of highly compacted granular material act as a flexible reinforcement in the soil to increase the overall shear strength of the treated soil. During the process of column installation, sandy soil between the columns is densified Design The responsibility of design and execution of stone column works was given to Keller. Curve A in Figure 5 shows the required CPT for no liquefaction as per Stark & Olson (1995). Curve B shows the existing Qc which is less than the theoretically required value. Ground improvement works were designed using the Priebe method. The installation of well compacted stone columns which are able to carry a large portion of the shear forces during an earthquake results in a reduction in the requirement for the Qc value in the soil between the columns (now shown by curve C). As per the design, 1.0 m diameter columns on a square grid spacing of 2.4 m c/c to a depth of 16 m from the existing ground level were to be installed. The annular width of treatment was extended beyond the tank edge by 10 m. Cone Resistance (MPa) Curve A - Required Qc with out SC Curve B - Pre CPT Curve C - Required Qc with SC Curve D - Post CPT Figure 5: Typical CPT test results Depth (m)

7 R. Wegner Dr. V. R. Raju A.Vetriselvan 3.4. Column Installation and Quality Control The columns were installed using the Keller S230 vibrator. The column installation process was monitored using the computerized M4 monitoring system. The position and the current drawn by the vibrator were continuously measured online and displayed to the operator. A hard copy was also produced for review by the Engineer. The hard copy consist of two curves 1) Depth Vs Time and 2) Current Vs Time. The typical print out is shown in Figure 6. The left curve shows the time on the vertical axis and depth on the horizontal axis. This plot provides a comprehensive record of the movement of the vibrator. There are three distinct phases of installation. The first phase is penetration of the vibrator to the required depth for the first time. In the second phase, the hole is flushed by withdrawing the vibrator and repenetrating in to the hole. In the third phase, the vibrator is lifted up by about 1.0 m and then repenetrated by about 0.7 m in to the stone mass to form a highly compacted stone column. The plot shows the entire length of the stone column built up to the required level. The plot on the right side shows current drawn by the vibrator on the horizontal axis and time on the vertical axis. The current drawn is used as an indicator of the compactive effort of the vibrator. It can be seen that as the vibrator repenetrates the column, there is a sharp increase in the amperage indication compaction. CPT tests were carried out 7 days after column installation was completed. Curve D in Figure 5 shows a typical post column installation CPT result. The curve shows that the post CPT values are well above the required values. At certain depths lenses of cohesive soils reduced the test results to values similar to the original value. However, these cohesive lenses are not susceptible to liquefaction. Figure 6: Typical M4 column installation record CONCLUSIONS Post compaction CPT testing has shown that Vibro Compaction is a reliable technique for the offshore densification of loose sands at Karwar. Similar testing has also proven that Vibro Replacement is able to mitigate liquefaction potential and reduce settlements to within tolerance limits for large and settlement sensitive LNG tanks at Hazira. In the case of the LNG tank foundation, Vibro Replacement has proven to be economical as compared to conventional rigid foundations which require extensive reinforcement to counter large horizontal forces in the event of an earthquake. 6

8 Application of Vibro Techniques for Infrastructure Projects in India REFERENCES Priebe, H.J. (1995), The Design of Vibro Replacement, Ground Engineering Vol 28, No 10. Priebe, H.J. (1998), Vibro Replacement to Prevent Earthquake Induced Liquefaction, Ground Engineering Vol 39, No 10. Raju, V.R., Wegner. R., Godenzie. D. (1998), Ground Improvement using Vibro Techniques Case Histories from S.E. Asia, Ground Engineering conference Stark, T.D. and Olson, S.M. (1995), Liquefaction Resistance Using CPT and Field Case Histories, Jl of Geotechnical Engineering, ASCE,

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