Proceedings of the First International Conference on Press-in Engineering 2018, Kochi
Design and Installation of a Permanent Sheet Pile basement for the Manly
Twenty95 Development
Davide CANTALI
Senior Sales Engineer , J Steel Australasia Pty Ltd
Email: [email protected]
Taro ITO
Project Manager, J Steel Australasia Pty Ltd
Email: [email protected]
ABSTRACT
Manly Twenty95 project is a luxury 6 story (24 apartment) residential development currently under construction in
Sydney Australia. J Steel Engineering had been constructed the permanent 4 level basement for an integral automated
carpark storage facility for this development in March 2018 using the ECO600S Silent Piler. Approximately 100m of
sheet pile wall was required for the basement structure. 21m long, 600mm wide hot rolled U piles were installed with
the Super Crush system in dense to very dense sands to support excavation depths of up to 12.5m. The bottom-up
technique with temporary propping was adopted by the builder. This paper identifies and discuss the design and
construction challenges for the permanent sheet pile basement, including; supporting large vertical column loads on the
sheet pile wall, durability aspects for providing a life beyond 50 years, and interfacing with temporary and permanent
lateral supports. In addition, the paper emphasizes interesting aspects related to the installation of the sheet pile system,
including use of the Super Crush for installing long sheet piles and problem solving of any other issues that arised
during the works.
Key words: Giken ECO600S, Permanent Sheet Pile Basement, Design, Axial load
1. Outline of the project
1.1. Place
The project site is located on the corner of the busy
intersection of Belgrave Street and Sydney Road in Manly,
Sydney, NSW Australia – a 5min. walk from the surf
beach and opposite to Manly Oval. Adjacent to the site is
an existing telecommunications exchange and a heritage
listed sandstone church (Fig. 1). Fig. 1 Site location
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Proceedings of the First International Conference on Press-in Engineering 2018, Kochi
1.2. Background and objectives of the project
The project site is a small congested site Table 1. Idealised geotechnical design profile
2
approximately 1000m in area. Grocon are developing the Top of Cone
site into 4 levels of 1, 2 & 3 bedroom luxury apartments in unit resistance
Material Consistency
addition to some commercial and retail space. To service (RL m qc
the building, a 4 level automated carpark within a AHD) (MPa)
permanent basement will be constructed. A maximum 5.50 Sand (Fill) 10 Variable
excavation depth of ~12.5m is required to construct the 4.50 Sand 5 Loose
carpark. 1.00 Sand 10 Medium Dense
-11.70 Sand 28 Dense to Very
2. Structural type and piling method Dense
2.1. Site condition
The site is within the busy commercial/residential
precinct of Manly and was formerly used as a
park/carpark (Photo 1).
Due to the restricted site space and concerns
regarding noise within the retail area and vibration
damaging heritage listed buildings, suitable retaining wall
systems were carefully considered.
Photo 1. Site Image
2.2. Ground condition
The site is underlain by Quaternary sediments
comprising medium to fine grained marine sands. In this
part of Manly, the sediments typically overlie
Hawkesbury Sandstone at depths of 36 m to 39 m (Table
1 and Fig. 2).
The groundwater table is high, about 4m below
existing ground surface (+5.5m AHD).
A number of CPT’s and sampled boreholes were
completed on site indicating loose to medium dense sand
becoming dense then very dense. Fig. 2 Bore Hole Data
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Proceedings of the First International Conference on Press-in Engineering 2018, Kochi
2.3. Structural type & design The conventional sheet piles installation method
The project required a permanent basement wall for using a vibration hammer was NOT recommended for
a design life of 50 years. The basement would be the use on this site as there were movement sensitive
constructed bottom up and required a maximum 12.5m structures adjacent to the excavation. We proposed the
excavation. In the temporary case, the walls would be Press-in Piling method using our ECO600S with the
supported by temporary anchoring and bracing, and by design described below.
concrete slabs at each of the basement slab levels in the
permanent scenario. A PU22 pile section, supplied as 600mm wide U
piles, was determined as the preferred section to support
The initial Geotechnical report provided by the the earth and water pressures in the temporary and
client suggested for the retaining wall system either of; permanent case (Fig. 3).
1) A secant pile wall comprising interlocking
Continuous Flight Auger (CFA) piles or CFA piles with
jet grouted columns between the piles.
2) Soil mixed wall systems constructed using
specialised equipment to either blend cement with the
in-situ soils to create a soil-cement mix.
Fig. 3 PU22 pile properties
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Proceedings of the First International Conference on Press-in Engineering 2018, Kochi
As per the client design requirement the walls also permanent columns supporting the superstructure above.
had to support permanent surcharge load from the The maximum factored column loads of up to
adjacent pedestrian footpaths and roadways (up to 2141kN were supported on 2, 3 or 4 U piles. Fig. 5
20kPa) as well as temporary construction load from the shows column loading. Also the sheet pile/wall was
plant, equipment and materials (up to 50kPa). required to provide cut-off to limit groundwater flow into
Fig. 4 section view shows a typical design the excavation.
arrangement for the permanent case.
In addition to supporting earth and water pressures,
the walls were required to support axial load from
Fig. 4 PU22 pile properties
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Proceedings of the First International Conference on Press-in Engineering 2018, Kochi
Fig. 5 Column Loadings
2.4. Durability jetting operation, and a possible disturbance to nearby
In accordance with the Australian Standard AS2159, ground/ structure by high pressure jetting, J Steel
the site was classified as non-aggressive to steel piling. A proposed the press-in with augering with ECO 600S.
corrosion allowance of 0.025mm/yr was allowed on the
front and back faces of the wall, reducing thickness by 3. Press-in piling
1.25mm per side over 50 years (2.5mm overall). In 3.1. Layout
addition, on the inside within the basement excavation, The layout of the sheet piles can be seen in Fig. 6.
the sheet piles will be painted and maintained for a 25 The sheet pile length varies depending on the excavation
year life. depth.
The appropriate reductions in section modulus and
moment of inertia were determined and applied in the
design calculation to confirm satisfactory structural
performance at end of life.
2.5. Piling method
The geotechnical report stipulated to conduct further
testing to determine the appropriate disposal options of
ground water as it detected hydrocarbons within the
samples collected from the monitoring well.
Initially the press-in with water jetting was planned.
However, considering the counter measure against
possibly contaminated groundwater collected from the
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Proceedings of the First International Conference on Press-in Engineering 2018, Kochi
3.3.2. Site personnel
The site personnel to execute the works are listed
below;
- T. Ito – Engineer (J Steel)
- T. Ueta – Operation of ECO 600S (Giken)
- M. Machida – Leading hand (Giken)
- K. Fukumori – Offsider (Giken)
- C. Carde – Supervisor (Keller)
- L. Copley – Welder (Keller)
- R. Coombes – Offsider (Keller)
- 80 Ton Crane Operator (Keller/ WGC)
- 30 Ton Crane Operator (Keller/ WGC)
Fig. 6 Layout of Sheet Piles
3.2. Productivity 3.4. Encountered difficulties
We used 1 no. x press-in machine (ECO 600S) for 3.4.1. Delay of existing sub-station removal
entire project. The outline of our program on the site is We mobilised resources on 13/12/2017 based on the
described in Table 2; Sub-station located within the site would be removed in a
Table 2. Outline of Site Program week time. However this did not happen until 27/2/2018.
This delay had resulted in significant low productivity
and increase of work load. We were also forced to reduce
our storage area and increased congestions on the site.
The originally planned foot print was as per below Fig. 7.
This was changed drastically due to the existence of the
Sub-station. Cranes were needed to increase their
capacity to enable to reach longer distance. Sheet piles
were needed to store on top of the existing Telecom
Noticeably, the actual working (piling) day was 34 Building.
out of 60 business days we stayed on the site. The causes
of the stand down of our resources will be explained in the
next section.
The maximum length of sheet pile installed within a
day was 9 Sheets x 21.0m = 189 m which was recorded on
17-January 2018.
3.3. Resources
3.3.1. Major plant and equipment
The major equipment use on site are listed below;
- 1 no. Press-in ECO 600S - Giken/ JSteel
- 1 no. 80 ton Crawler Crane - Keller/ WGC Fig. 7 Planned Foot Print
- 1 no. 30 ton Crawler Crane - Keller/ WGC
- 1 no. 250 cfm Air Compressor - Keller/ Coates The existence of Sub-station also affected the
- 1 no. 5 ton Excavator - Keller/ Coates sequence of our piling works. Closing the sheet pile wall
- 1 no. Welding Machine – Keller as a “box” (clutched) required a careful planning.
- 1 no. Oxy Cut set – Keller Closing at a 90 degree corner is a normal practice as it
provides greater flexibility to absorb material and
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Proceedings of the First International Conference on Press-in Engineering 2018, Kochi
construction tolerance. However due to the existence of existing cables close to the site boundary had been
sub-station we needed to re-plan the piling sequence and identified and protected.
compromised to close the wall at 45 degree (Number 6 at
Fig. 7), which eventually took us for a few days to close
because of the the limited flexibility compare to a 90
degree corner and the deviation of the wall was more
than what we anticipated.
Moving the Piler from one place to another took
about half a day. The 27m casing auger was required to
be removed and dismantled. Associated plant and
equipment need to be re-organised.
Initially we anticipated only twice for moving the
Piler. But after we changed the sequence we had to move
5 time which increased 3 movements from the original
plan.
Fig. 8 Piling Platform Level
3.4.2. Piling platform level issue
1m deep x 2m wide trench was to be excavated 3.4.3. Tolerance of sheet pile material
along the perimeter line before we commence the piling The Fig. 9 shows the comparison between the actual
works. However the client found an existing high voltage distance and the design distance of sheet pile walls. As
cables along the boundary line and could not create the can be seen approximately 270mm was lengthened due
trench (Fig. 8). to extra 5-6mm width of each sheet pile.
The failure to excavate over the boundary resulted These extra lengths were absorbed at the corner
in extending piles for 1m and slower productivity while which had greater flexibility.
Fig. 9 Tolerance of Sheet Pile Material
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Proceedings of the First International Conference on Press-in Engineering 2018, Kochi
3.4.4. Ground Movement due to Pre-Drilling
As can be seen in the Photo 2 and 3, we observed
some crack and subsidence were caused, possibly by our
augering works along the perimeter.
The client used plywood and fence posts and
excavated the site about 1m before we commence our
works (refer to Photo 1).
Patched repair of path was done by the client and
fortunately no serious damaged been observed.
Fig. 10 Contractual Formation
Photo 2. Pedestrian Path 1
4. Concluding remarks
This paper described the outline of the project
including how we carried out the design for the basement
as well as the construction works. We particularly spent a
space for problems we encountered on site which we
would like to share with other members for future use.
5. Acknowledgements
This project would not have been possible without
full support from Giken's personnel from the tender stage
to the completion of the site works. We would like to
Photo 3. Pedestrian Path 2 extend our sincere appreciation to all of Giken team.
3.4.5. Execution team on site References
Fig. 10 shows the contractual formation of the Australian Standard 2159. 2009. Piling - Design and
project. Although we had engaged with a well-known Installation, Council of Standards Australia.
specialist contractor, Keller, they had no experience in Douglas Partners Pty Ltd. 2016. Geotechnical
press-in operation. Therefore, we had 3 members from Investigation, Proposed Residential Development,
Giken including an experienced operator during the 85028.00.R.001.Rev1.
course of the project to ensure we provide the best J Steel. 2017. Design Report – Sheet Pile Wall,
performance. JE-7003-DR-04.
Arcelor Mittal. 2017. Arcelor Mittal Sheet Piling.
Catalogue.
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