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PROJECT
OF
SILOS
KARBALA CEMENT PLANT
KARBALA GOVERNORATE/IRAQ
Prepared by:
ROCK COMPANY
FOR
For Client:
KARBALA CEMENT PLANT
LAFARGE COMPANY
OPTIMUM COMPANY FOR GENERAL CONTRACTING AND
ENGINEERING
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The Rock Company for Soil Investigation and Wells Drilling
2017 Soil Investigation Report/Silos/Karbala Cement Plant/Karbala
Prepared by:
ROCK COMPANY
FOR
For Client:
KARBALA CEMENT PLANT
LAFARGE COMPANY
OPTIMUM COMPANY FOR GENERAL CONTRACTING AND
ENGINEERING
This report may be used only by the client and only for the purposes stated, within a
reasonable time from its issuance, but in no event later than 3 years from the date
of the report. Land or facility use, on and off-site conditions, regulations, or other
factors may change over time, and additional work may be required with the
passage of time.
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Based on the results of our field investigation, laboratory testing, and engineering
analyses, it is our professional opinion the site may be developed for the proposed Silos
using conventional grading and foundation. Recommendations regarding the
geotechnical aspects of project design and construction are presented in the following
report.
We appreciate the opportunity of providing our services for this project. If you have
questions regarding this report or if we may be of further assistance, please contact the
undersigned.
Sincerely,
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2017 Soil Investigation Report/Silos/Karbala Cement Plant/Karbala
TABLE OF CONTENTS
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LIST OF SYMBOLS
Symbol Definition
ASTM American Society for Testing Materials
BH Borehole
BS British Standards
c Cohesion
CH High plasticity clay
CL Low plasticity clay
Cc Compression Index for Normally Consolidated Soil
Cl-1 Chloride content
Cs Swelling Index for Over Consolidated Soil
cv Coefficient of vertical consolidation
DS Disturbed soil sample
EGL Existing ground level
eo Initial void ratio
FFL Finishing floor level
Gs Specific gravity
GWT Ground water table
k Coefficient of permeability
L Length of pile
LL Liquid limit
mv Coefficient of volume compressibility
MH High plasticity silt
ML Low plasticity silt
N Standard penetration test value
N60 Corrected standard penetration test value
NGS Natural Ground Surface
NP Non-Plastic
OM Organic matter content
Pc Preconsolidation pressure
Ps Swelling pressure
PCA Portland Cement Association
PI Plasticity Index
PL Plastic limit
SL Shrinkage limit
SP Poorly graded sand
SW Well graded sand
SO3 Sulfur trioxide content
SPT Standard Penetration Test
SS Split spoon sample
T Thickness of consolidated clay layer
TSS Total soluble salts
US Undisturbed soil sample
USCS Unified Soil Classification System
WWTP Waste Water Treatment Plant
Z The seismic zone factor
dry Dry density
t Total density
n Water content
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2017 Soil Investigation Report/Silos/Karbala Cement Plant/Karbala
1 INTRODUCTION
This report has been prepared by the Rock Company for Soil Investigation and Wells
Drilling, but the tests of soil samples for this project have been conducted by the
College of Engineering/University of Baghdad according to the authorization of
Optimum Company for General Contracting and Engineering via their official letter
No. No dated on 21/5/2017. This report presents the results of geotechnical
investigation for the proposed Silos Project at Karbala Cement Factory in Karbala
Governorate at the west of Iraq. A site location image is presented on Plate 1. The
following sections of this report describe the geotechnical properties of soils in the
locations of project and brief description about the parts of the project.
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basin above sea level. Uplift period designated disappear of Touronian age in the south
Iraq.
Geologic mapping for the site which is consider part of Karbala region has been
performed at the State Establishment of Geological Survey and Mining as shown in
Plate 2. The geologic formation of site is belonging to Holocene age which consists of
Aeolian deposits underlying flood plain deposits (fluvial deposits) of Euphrates River
which belonging to Pleistocene period. The geology of Karbala site consists of marsh
deposits, mud with organic material (symbol Qm) and shallow depression
deposits/sabkha (symbol Qd) as shown in Plate 2. However, the site is free from erosion
old rock surface. On the other hand there is depression fill deposits which accumulate
due to successively floods as shown in Plate 3.
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2017 Soil Investigation Report/Silos/Karbala Cement Plant/Karbala
Zone I II III
Value of Z 0.05 0.07 0.09
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3 SITE CONDITIONS
Discussions of the field investigation and laboratory testing programs are presented in
Appendices A and B, respectively, of this report. Detailed descriptions of the subsurface
conditions encountered during the field investigation are presented on the Logs of
Borings in Appendix A. Laboratory test results are provided on the boring logs and in
Appendix-B. The following sections describe the general site conditions that
interpreted from the available topographic, subsurface and laboratory test data.
The average annual rainfall was 91.9 mm for duration from 1970 to 2011. The probable
maximum rainfall intensity for duration of one hour was about 33.8 mm/hrs happened
in 8/12/1992. However, in spite of that the rainfall and other climatic elements causes
changes to the moisture contents of subsurface layers and may direct influencing the
stability and strength of these materials, the amount of rainfall in the investigated area
is insufficient and is considered to be very low rainfall unaffected to engineering
properties of the soil.
3.4. Groundwater
At the time of field investigation 16th of May 2017, the groundwater table in the drilled
borehole depends on the ground level. The groundwater is far from the ground surface
and due to the shallow depth of coring. The groundwater table may be changed due to
seasonal variation.
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may not be required within earthwork cut areas consisting of cemented soils if approved
by the project Geotechnical Engineer during construction. In-place scarification and
compaction may not be adequate to densify all disturbed soil within areas grubbed or
otherwise disturbed below a depth of about 20cm. Therefore, over-excavation of
disturbed soil, scarification and compaction of the exposed subgrade, and replacement
with engineered fill may be required to sufficiently densify all disturbed soil.
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Heavy construction equipment, building materials, excavated soil, and vehicular traffic
should not be allowed within 1/3 the slope height from the top of any excavation. Where
the stability of adjoining buildings, walls, or other structures is endangered by
excavation operations, support systems such as shoring, bracing, or underpinning may
be required to provide structural stability and to protect personnel working within the
excavation. Shoring, bracing, or underpinning required for the project (if any) should
be designed by a professional engineer. During wet weather, earthen berms or other
methods should be used to prevent runoff water from entering all excavations. All
runoff water and/or groundwater encountered within the excavation(s) should be
collected and disposed of outside the construction limits.
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of these utilities and backfill materials may be necessary. Alternatives for stabilization
include shoring or bracing systems, and various in-situ compaction or permeation
grouting methods.
The stabilization method chosen for support of adjacent utilities (and backfilling)
should be determined based on a thorough review of existing conditions and with the
approval of the utility owner. The proposed shoring system design should be reviewed
by the design tea to evaluate whether the proper soil parameters have been used and the
anticipated shoring deflections are within the tolerance established by the owners of
adjacent improvements that may be affected by nearby trench installations. The
Contractor should use means and methods that will limit vibrations at the locations
adjacent structures/facilities. Where construction operations such as sheet pile driving
demolition, or similar activities induce significant ground vibrations near critical
facilities. More stringent requirements may be needed adjacent to historic structures,
buildings in poor condition, or buildings where vibration sensitive equipment is being
operated.
The most common chemical reactions caused by chlorides and sulfates. Chlorides,
particularly calcium chloride, have been used to shorten the setting time of
concrete. However, calcium chloride and sodium chloride have been shown to
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leach calcium hydroxide and cause chemical changes in Portland cement, leading to
loss of concrete strength, as well as attacking the steel reinforcement present in most
concrete. Accumulation of critical concentrations of chloride ions in the vicinity of the
steel can initiate corrosion. Sulfates in solution in contact with concrete can cause
chemical changes to the cement, which can cause significant microstructural effects
leading to the weakening of the cement binder (chemical sulfate attack). Sulfate
solutions can also cause damage to porous cementation materials through
crystallization and recrystallization (salt attack).
Sulfates are ubiquitous in the natural environment and are present from many sources,
including gypsum (calcium sulfate) often present as an additive in 'blended' cements
which include fly ash and other sources of sulfate. With the notable exception of barium
sulfate, most sulfates are slightly - highly soluble in water. The chemical analysis of
soil and groundwater samples is important to get the necessary data for the durability
of foundation through providing protection against chlorides and sulfates attacks. The
necessary data, summary of soil samples are given in Table 3.
, =
,
, =
= , +
= , + = +
Where
qult = ultimate bearing capacity;
qult, net = ultimate bearing capacity;
qall = allowable bearing capacity;
qall, net = allowable bearing capacity;
FS = factor of safety (assumed to be 3);
Df = depth of footing placement.
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1) The applied load must not cause shear failure in the soil (evaluating the ultimate
bearing capacity and using suitable factor of safety).
2) The settlement must not be excessive, beyond the allowable values.
During the last sixty years, several bearing capacity theories were proposed for
estimating the ultimate bearing capacity of shallow foundations. Generally, the most
bearing capacity could be evaluated from one of the following method:
Where:
c' = cohesion;
q = effective stress at the level of the bottom of the foundation = Df;
= unit weight of soil;
Df = is the depth of footing placement;
B = width or diameter of foundation;
Nc, Nq, N = bearing capacity factors (functions of the soil friction angle, );
Where:
, , = shape factors;
, , = depth factors;
, , = load inclination factors.
Where:
, , = base inclination factors;
, , = ground factors;
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Where:
Qp = load-carrying capacity of the pile point;
Ap = area of pile tip;
qp = unit point resistance;
c' = cohesion of the soil;
q' = effective vertical stress at the level of pile tip;
Nc , Nq , N = the bearing capacity factors;
Qs = frictional resistance (skin friction);
p = perimeter of the pile section;
L = incremental pile length;
f = unit friction resistance at any depth z.
= =
.
= ( )
Where
C = 0.4 to 0.5 for bored piles and 0.5 for driven piles.
o = average effective overburden pressure.
The bearing capacity for different types of foundations is concluded from the results of
standard penetration tests and interpolated for the in between depths. The values of
bearing capacity given in Table 4 are based on factor of safety equal to 3 and the
consolidation settlement must be checked to be within allowable limits as listed in
section 4.3.7. The factor of safety is assumed to be 3 due to low friction between the
wall of bored pile and soil resulting from the silty clay nature of site soil.
The magnitude of bearing capacity for surface layers of soft soil can increased by soil
replacement, in such case the bearing capacity used in calculations of foundations
dimensions will be one at the depth of excavation and the addition weight resulting
from using well compacted soil layers should be taken into consideration. Nevertheless,
for deep layers of soft soil and for economical purposes, we should change the type of
foundation to be deeper than the depth of soft soil.
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qall
BH No.
Ton/m2
BH1 23.0
BH2 14.7
BH3 18.5
Shallow foundations: are placed at shallow depths i.e. D < B or where D is less than
about 3m (i.e. within reach of normal excavation plant).
Pile foundations: transmit the loads to greater depths through steel or reinforced
concrete columns.
0.65 12 Es B4 Es
ks =
B EF IF 1 2
Where:
Es is the modulus of elasticity of soil;
B is the foundation width;
EF is the modulus of elasticity of footing;
IF is the moment of inertia of footing;
is Poisson's ratio.
Since the twelfth root of any value 0.65 will be close to 1, for all practical purposes
the Vesic equation reduces to:
Es
ks =
B(1 2 )
The value of Es can be calculated from the results of odometer tests given the
Appendix-B of the report by plotting stress-strain relationship. The value of Poison's
ratio can be assumed to be 0.2.
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For simplicity of finding the modulus of subgrade reaction, Bowels (1997) suggested
the following formula for approximating the ks value:
k s = 40 (FS) qall
Where
FS is the factor of safety to be taken 3;
qall is the allowable bearing capacity.
BH No. Ks (MN/m3)
BH1 27.87
BH2 17.64
BH3 22.20
The fill material (Section 4.2) should be taken from an approved, designated borrow
area. It should be free of roots, stumps, wood, rubbish, stones greater than 6 inches, and
frozen or other objectionable materials. Fill material for the center of the embankment
should conform to Unified Soil Classification GC, SC, or CL. Consideration may be
given to the use of other materials in the embankment based on the recommendations
of a geotechnical engineer supervises the design and construction. The maximum
dimension of any particle of the material may not be greater than the loose lift
thickness. Any particles that are larger than the loose lift thickness must be removed
and disposed of, or may be put in the embankment side slope. The use of select fills
was not a primary concern of the respondents. The compatibility of the existing
embankment soil with the new fill with respect to permeability was considered
important. The survey results also indicate that unreinforced slopes up to 2:1 (H:V) are
typically used for embankments.
The area on which fill is to be placed should be scarified before its placement. Fill
material should be placed in layers a maximum of 20cm thick (before compaction),
which should be continuous over the entire length of the fill. The most permeable
borrow material should be placed in the downstream portions of the embankment. The
principal spillway must be installed concurrently with fill placement and not excavated
into the embankment.
The fill material should be compacted with appropriate compaction equipment such as
a sheep's foot, rubber-tired or vibratory roller. The number of required passes by the
compaction equipment over the fill material may vary with soil conditions. Compaction
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4.3.6. Settlement
For foundations designed and constructed in accordance with the recommendations in
this report and under static loading conditions, total post-construction foundation
settlement is expected to be calculated using the following equation (for more details
see Appendix-D). Post-construction differential settlement is expected to be about half
of the total settlement.
=
+
Where
Sc: is consolidation settlement.
H: is thickness of clayey soil layer;
eo: is initial void ratio;
e: is change in void ratio.
=
=
Where
Cc: is the compression index,
Cs: is the recompression index or swell index.
Total Differentiable
Type
Type of footing settlement settlement Reference
of soil
mm mm
Isolated and Strip 25 - Terzaghi and Peck, 1967
Slab and raft 50 - Tomlinson, 1980
Sand
Isolated and Strip 40 51
Slab and raft 45-65 51-76 Skempton and
Isolated and Strip 65 76 McDonald, 1956
Clay
Slab and raft 65-100 76-126
Its recommended to adopt the values presented by Skempton and McDonald (1956)
in checking the settlement of structures foundation.
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A capillary break may not be required for some types of construction (such as
warehouses, equipment buildings, garages, and other non-habitable structures). For
these types of structures, the gravel capillary break recommended above may be omitted
and the slab placed directly on a minimum 20cm thick layer of compacted sub base
material (sand-gravel mixture). The material should be compacted to at least 95 percent
relative compaction at a moisture content slightly above optimum.
To reduce the potential for under slab moisture problems, we recommend that floor
slabs be established 15cm or more above surrounding final grades. Drainage should be
provided for planters adjacent to buildings such that water does not accumulate against
foundations.
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depends on the landscaping type. In general, pavement and lawns within 1.5m of
buildings should slope away at gradients of at least two percent.
In general, the elevation of exterior grades should not be higher than the elevation of
the subgrade beneath the slab to help prevent water intrusion beneath slabs. In any
event, maintenance personnel should be instructed to limit irrigation to the minimum
actually necessary to properly sustain landscaping plants. Due to excessive irrigation,
waterline breaks, or unusually high rainfall occur, saturated zones and "perched"
groundwater may be developed. Consequently, the site should be graded so that water
drains away readily without saturating the foundation or landscaped areas. Potential
sources of water, such as water pipes, drains, and the like, should be frequently
examined for signs of leakage or damage. Any such leakage or damage should be
promptly repaired. All utility trenches that pass beneath perimeter foundations should
be backfilled with compacted non-pervious fill material or a lean concrete trench plug
to reduce the potential for external water to migrate beneath the building through the
utility trenches. Special care should be taken during installation of sub-floor water and
sewer lines to reduce the possibility of leaks.
Proper moisture conditioning and compaction of subgrade soils is important. Even with
proper site preparation, we anticipate that over time there will be some effects of soil
moisture change on concrete flatwork. Exterior flatwork will be subjected to edge
effects due to the drying out or wetting of subgrade soils where adjacent to landscaped
or non-paved areas. To help reduce edge effects, lateral cutoffs such as a thickened edge
are suggested. Control joints should be used to reduce the potential for panel cracks as
a result of soil displacement. Steel reinforcement will aid in keeping the control joints
and other cracks closed. Exterior concrete slabs-on-grade should be cast free from
adjacent footings or other non-heaving edge restraints. This may be accomplished by
using a strip of 12.5cm asphalt-impregnated felt divider material between the slab edges
and the adjacent structure. Frequent construction or control joints should be provided
in all concrete slabs where cracking is objectionable. Dowels at the construction and
control joints will also aid in reducing uneven slab movements.
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5.2. Recommendations
1) The natural ground must be compacted before starting any structure fill.
2) For deep excavation, designed braced wall (shoring) should be used.
3) The ground must be sloped away from structures as much as possible one of the
most practical and economical methods are through use of compaction control for
the backfill of the zone around the foundation with well-compacted layer of low
permeability. Those slope maintained so that runoff water will be carried away from
adjacent to stand near foundations, but must be drained into lined ditched.
4) Drainage pipe lines of water, sewers, and gas must be installed in such a way that
not make weakness of the foundations and should be designed to absorb movement
without breaking, these pipes also must be well fixed and laid with permeable
material cover all around.
5) Using expansion joints between columns and floor slab for long buildings and
fence.
6) Using a good rainfall drainage system to collect the rainfall from the site and out
the site.
7) It's recommended to protect the pavement from rain water and any other water
(surface and underground water), by using a good side ditch along all the road side
in the right-of-way of the road. Normal cross slopes including camber must be done
in slop not less than 1/50.
8) Soil replacement: it is recommended to use the following layers under all types of
foundation, isolated and strip.
a) Two layers of well-compacted sub-base (mixture of gravel and sand) of 30 cm
thickness after well compaction decided by the designer engineer of foundation.
9) The zone beside the roads (shoulders) should be filled with a well-compacted clayey
layer of low permeability according to (ASTM D-1557) to conform required a non-
permeable layer.
10) Using the sulphate resistant Portland cement in all concrete works in contact with
soil. The minimum cement content of 370 kg/m3 for maximum size of gravel 20mm
and water/cement ratio is 0.45 by weight. The cement content must be increased by
100 kg/m3 in case of using pile foundation. In addition, the minimum compressive
strength of concrete is 30 MPa.
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11) The Gypsum content in the surface layer exceed 5%, so its important to take into
consideration in the design of footing and prevent surface water and groundwater
from reaching the silos foundations to avoid the dissolution of gypsum.
12) All concrete that is in contact with soil should coated with bitumen material at the
base and sides of the foundation.
13) Its recommended to use allowable bearing capacity of 18.5 Ton/m2 in the design of
footing to avoid the differential settlement of footings.
5.3. Limitations
The Rock Company for Soil Investigation and Wells Drilling has prepared this report
for the Optimum Company for General Contracting and Engineering, the project of
silos to be constructed at Karbala Cement Plant for use in the design of foundation of
the proposed Silos in Karbala Governorate, Iraq. This report prepared in substantial
accordance with the generally accepted geotechnical engineering practice, as it exists
in the project area at the time of our study. No warranty, express or implied, is made or
intended. It is likely that soil conditions vary between or beyond the locations that we
have explored to date. Land use, site conditions (both on-site and off-site) or other
factors may change over time, and additional geotechnical exploration may be required
if the construction plan or schedule changes. Only Project owner may use this report,
only for the purposes stated, and within a reasonable time from its issuance. Any party
other than the building owner who wishes to use this report shall notify the Project
owner of such intended use. Based on the intended use of the report, the Rock Company
for Soil Investigation and Wells Drilling may require that additional work be conducted
and that an updated report be issued. Noncompliance with any of these requirements by
the client or anyone else will release the Rock Company for Soil Investigation and
Wells Drilling from any liability resulting from the use of this report by any
unauthorized party.
The conclusions and recommendations submitted in this report are based upon the data
obtained from subsurface explorations agreed by the Optimum Company for General
Contracting and Engineering. The recommendations contained herein are not intended
to dictate construction methods or sequences. Instead, they are furnished solely to help
designers identify potential construction problems related to foundation and earth plans
and specifications, based upon findings derived from sampling. Depending upon the
final design chosen for the project, the recommendations may also be useful to
personnel who observe construction activity.
6 REFERENCES
Al-Khafaji, A.W. and Andorslang O.B. (1992): "Geotechnical Engineering and Soil
Testing", S. Ink. USA.
American Association of State Highway and Transportation Officials (AASHTO).
American Concrete Pipe Association (2000), Concrete Pipe Design Manual, Revised.
American Lifelines Alliance (2001), Guidelines for the Design of Buried Steel Pipe.
American Society of Testing Materials, ASTM, (2004): "Soil and Rock".
Bowles, J. E. (1997), "FOUNDATION ANALYSIS AND DESIGN", fifth edition,
McGraw- Hill Companies, Singapore.
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British Standard Institutions (1975): "Methods of Testing Soil for Civil Engineering
Purposes", B.S., 1377.
Budh, M. (2000): "Soil Mechanics and Foundation", John Wiley and Sons Inc., USA.
Craij, R.F (2003): "Craij's Soil Mechanics", 7the edition Spoon Press, London,
England.
Das, B.M (2011): "Principles of Foundation Engineering", Seventh Edition, Thomson
Brooks/ Cole, USA.
Howard, A.K., (1996), Pipeline Installation, by Relativity Publishing, Lakewood,
Colorado.
Lambe, T.W. (1951): "Soil Testing for Engineering", John Wiley and Sons, Inc., USA.
Spangler, M.G. and Handy, R.L. (1982), Soil Engineering, 4th Edition, Harper & Rowe,
New York, NY.
Peck, R.P; Hanson, W.E. and Thornburn, T.H. (1974): "Foundation Engineering", John
Wiley and Sons Inc., USA.
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APPENDICES
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APPENDIX A
FIELD INVESTIGATIONS
1. General
The subsurface soil conditions at the site of project were explored 16th of May 2017 by
drilling three boreholes to a depth of 6m below existing ground surface. Boring was
drilled using truck-mounted drill rigs equipped with 100mm-diameter coring auger.
The location and depth of borehole was specified under the structure of project directly
to get detailed information about the geotechnical properties of subsurface soil. The
field Logs and descriptions of Boring, visually classified soils encountered according
to the Unified Soil Classification System (Figures A-1 to A-3).
Disturbed and undisturbed soil samples were obtained from the subsurface materials to
be tested in the laboratory. Soil classifications were made in the field from samples and
auger cuttings in accordance with ASTM D 2488 (Visual-Manual Procedure). Sample
classifications, blow counts recorded during sampling after correction, and other related
information were recorded on the boring logs. Following laboratory testing, the visual
soil classifications made in the field were reviewed and reclassified in accordance with
ASTM D 2487.
2. Sampling Procedures
During the drilling operations, core soil samples were obtained from soil extracted
through the advance of auger into the subsurface soil, the core soil samples were used
for testing the physical, chemical and mechanical properties of soil. Core soil samples
obtained from the borings were packaged in wood molds to reduce disturbance, then
labeled and brought to Baghdad University/College of Engineering/Soil Mechanics
laboratory for testing.
3. Groundwater Measurement
After 24 hrs from completion drilling the groundwater table was measured by using
labeled rod from the ground surface.
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APPENDIX B
LABORATORY TESTING AND RECORDS OF TESTS RESULTS
1. General
Laboratory tests were conducted on selected soil samples to aid in soil classification
and to evaluate chemical, physical and mechanical properties of the soils that may affect
the geotechnical aspects of project design and construction. A description of the
laboratory testing program is presented below. A summary of the laboratory tests
performed are presented on the Records of Laboratory Tests Results, Tables B-1 to B-
5. Most of the laboratory test results are also included on the boring logs.
2. Physical Tests
2.1 Moisture Content
Moisture content tests were performed to evaluate moisture condition requirements
during site preparation and earthwork grading, soil overburden, and active and passive
earth pressures, and relative soil strength and compressibility. Moisture content was
evaluated in general accordance with ASTM Test Method D 2216. Results of these tests
are presented on the logs and are summarized on the Records of Laboratory Tests
Results. The soil samples are dry sand.
3. Chemical Tests
Selected samples of the subsurface soils encountered at the site were subjected to
chemical analysis for the purpose of corrosion assessment of concrete reinforcement
and sulphate attack assessment. The samples were tested for organic matter content
(ASTM D 2974), chloride content (BS 1377: Part 3: 1990, clause 7), total soluble salts
(ASTM D4542), sulfate content (BS 1377: Part 3: 1990, clause 5), and gypsum content.
The test results are summarized in the Records of Laboratory Tests Results, Table B-4.
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The Rock Company for Soil Investigation and Wells Drilling
2017 Soil Investigation Report/Silos/Karbala Cement Plant/Karbala
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The Rock Company for Soil Investigation and Wells Drilling