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1. Letter to Client
Superman S.I. Inc
Wonderland
Scotland
EH1 2AB
Thank you for your letter dated the 8th of January. I appreciate your concern and have
included below a list of possible risks that may arise as a result of the different
construction options for the Medway Tunnel.
Firstly I would like to address the possible geotechnical & construction risks associated
with the construction of the tunnel.
Were a shallow submerged tunnel to be considered, our primary concern would be the
design. As this is a relatively new technology in Britain, there will be little previous
experience to rely upon. This can be dealt with by bringing in an external expert to
advise, however a language barrier may cause further problems. It is also unlikely that he
will have a local knowledge of the soil conditions. Needless to say consultants will also
incur high costs.
Other concerns and solutions are listed below, however this is by no means an
exhaustive study (some of the risks below also apply to deep tunnels):
¾ The retaining wall around the excavated area could be subject to blow-ins. As this
is a brown field site, there is also the possibility that the excavation may unearth
some old piles or slabs remaining from previous structures.
¾ A naval base has been identified upstream and munitions can be expected to have
leaked into the soil. If this is localised then can be treated appropriately, however
it is a risk that contamination may enter the river in a larger burst than the
surrounding ecosystem has been accustomed to.
¾ A nearby building is listed. There is a possibility of structural damage due to the
ground settlement as a result of the dewatering process
If a deep tunnel is to be considered, the following risks should also be taken into account:
¾ Unexpected rock formations or metal ore may be met as a result of drilling under
the river bed
¾ Due to the deep nature of the tunnel, it will surface much further from the river
side than its shallow counterpart, as a result land may need to be purchased and
increased planning permissions obtained.
¾ The risk of tunnel collapse is very low but present.
¾ Depending on the permeability of the rock, pump failure during drilling may be a
reason for concern. As will be the circulation of air inside the tunnel if the
electricity supply fails.
Secondly, regarding the impact on the local community, there has been local support for
the project since its inception, given it will serve as a means to regenerate the area,
bringing business, whilst freeing space on the already congested bridges upstream.
However an inevitable amount of dust and dirt will be expelled into the air. Local
traffic patterns will not be significantly altered as construction will take place on
previously unused land. I cannot imagine noise being a concern as most construction
occurs below ground in an excavated pit, which acts as an inherent noise barrier.
As the site was formerly an industrial estate, the destruction of local wildlife is
not a main concern.
Finally, we will require the following information to efficiently plan out possible risks to
enable the smooth procession of the Medway tunnel:
Mr J. C. Smallwood
Engineer in Charge
To establish four initial layouts, tunnel section lengths of 125m and 93.75m have
been chosen and two varieties of each worked on. These were considered optimum
lengths as too long would raise problems with too much resistance against the flow of the
river, and too short would be uneconomical.
In selecting the site location, various criteria had to be taken into consideration.
The sites former use as a dock yard would ensure considerable foundations wherever the
casting basin was placed. To minimise the cost of removing foundation, the basin was
carefully positioned to avoid where possible the site of a demolished crane, or an
identified high pile risk area. With permission to demolish building no. 2, the choice was
taken in two cases to make use of this land, as it was assumed this would have fewer piles
than the no. 8 slipway. A brief overview of the 4 options can be seen in the table below:
Cost implications of the total excavated volume have also been taken into
account. Consequently, the smallest area was selected as the final option, taking into
consideration the associated foundation removal. This option can be seen below in
section 2.1.
2.1 – Option 1
2.2 – Option 2
39777.7m
2 This option offers the same benefits as option
3 x 125m 1 however it requires a greater excavation area,
incurring a larger cost, the excavation & muck-away
operation being the biggest price component of the
casting basin.
2.3 – Option 3
2.4 – Option 4
2
35656.8m Due to the slightly larger area, this option comes in
4 x 93.75
at slightly more expensive than option 3. however that cost
may be covered by the lack of need to remove so many
piles from the slip way, as it does not impose on it as much
as option 3. It also only requires the removal of one dock-
crane foundation. Building no. 2 has not been touched.
¾ Minimising risk
The dry load of the tunnel is found from calculating the area of the cross
section, and multiplying it by the materials’ density. In this case the density of the
concrete is 24kN/m3, for the purpose of this calculation it is assumed that this density
incorporates the steel reinforcement, cooling ducts and sandflow pipes within the
concrete. The calculation also assumes a standard cross section throughout the whole
length of the immersed tunnel, as displayed below:
1200
600
1200
9500 6800
1500
10450 10450
1000
25900
Loading: 24 x 87.93
2110.32kN per metre run of tunnel
The loading of the tunnel segments in their final immersed position is similar
to the dry load, with the addition of the ballast concrete within the tunnel and ballast
gravel surrounding the tunnel. As can be seen from the diagram, toes have been used
to make use of the gravel fill on the sides. For the purpose of this calculation, 2 metres
of gravel fill and 1 metre of concrete fill have been assumed. Previous assumptions
still apply.
600 1200
2000
1200
9500 6800
1000
1500
10450 10450
1000
25900
To ensure the tunnel sections can be sunk into their final positions, they must
first be able to float. This is a simple check of making sure the volume of water
displaced by the sealed tunnel section is heavier than the sealed section itself.
8000
9500
1500
25900
Dry Load
If < 1 , then the tunnel section will float when submerged.
Wet Load
2110.32
= 0.935
2256.8
When it is sunk into place, enough ballast has to be supplied to ensure it stays
immersed. The factor of safety against it floating can be investigated through a similar
calculation:
However this value of the bearing pressure incorporates a factor of safety of between
2.5 to 44:
9207.45
⇒ qp = = 2301.9 kN / m 2
4
9207.45
⇒ qp = = 3683.0 kN / m 2
2.5
5.3 Comparison
4
Dr Yummin Yang: Foundation engineering pile design
5
Copy can be found in attached spreasheet
Christian Smallwood (0345236) Page 17 of 32
Geotechnical Design Project The Medway Tunnel
Taylor's Method
Total Stress
Fill Method of Slices
Sandy Silt
Effective Stress
Silty Clay
0m OD
Chalk
3131,38
8171,02
35°
4200
10672,85
6
Craigs R.F.Soil Mechanics, 6th Edition, pp 377 - 381
Christian Smallwood (0345236) Page 18 of 32
Geotechnical Design Project The Medway Tunnel
cu La r
F= where W = γ × area
Wd
21×10.67 × 8.17
= = 1.66
352.65 × 3.13
cu
F=
N sγ H
21
= = 1.79
0.14 × 20 × 4.2
Using the values from the table above, the following equation can be used to
establish a factor of safety as above:
Total Effective
cu (kN/m ) φu (°) c’ (kN/m2) φ ' (°)
2
21 0 0 37
Table 10 – Effective & Total Stress Parameters
These values are much derived from engineering judgement. The value of cu is
taken from the scatter diagram executed in alluvial clay. The value of 21 can be
considered a conservative estimate. As it is an alluvial clay, the undrained angle of
friction is taken as 0. The effective cohesion of clay is also taken as 0, however the
effective angle of friction can be estimated using the N-value from the standard
penetration test. In this case, an N value of 34 returned a φ ' value of 37°.
Rate: £19.50/ m3
Rate: £275/m2
Quantity: 1 Crane
Rate: £175,000/year
This cost however is purely indicative, and does not include for a huge variety
of necessary operations, for example the dewatering pumps. An extensive study into
the cost of the casting basin would return a larger value
8. Soil Nailing
The process of soil nailing, originally a French technique, is extremely simple
in concept. By driving metal rods into a slope, the apparent cohesion will increase due
to their ability to handle tensile loads, hence increasing the stability of the slope. It is
in essence an in-situ soil reinforcement.
The drive behind soil nailing is the same drive behind the development of
multi story buildings, the constantly increasing sparsity of useable land. It is highly
popular on road and highway lane expansions, where instead of purchasing new land
upon which to construct, they simply increase the incline of the cut, as below:
However there are limitations to the application of soil nails, for instance the slope
concerned must be able to stand along before the nails are applied. The type of soil is
also a factor in its viability, as summarised in the table 12:
Practical Impractical
Clays Soft, plastic clays
Sandy Soils Organics/Peat
Weathered rock, Tallus slope deposits Loose, low density and/or saturated soils
Heterogeneous and stratified soils Fills (rubble, cinder, ash, etc.)7
Table 12 – Suitable & Unsuitable conditions for soil nailing
Thus whilst soil nailing would be an obvious solution in most scenarios, from
the bore hole log the soil is defined as “Very soft becoming soft […] silty clay…”,
making it impractical for the casting basin excavation. Were it to be an option, it
would potentially enable the placing of the casting basin to avoid the extensive pile
foundation in the slipway and the demolition of building no. 2.
Estimated costs of soil-nailing are about £100/m2, with approximately 3460 m2
of soil to nail, the total cost of soil nailing would be £346,000.008. This is a meagre
cost in the total casting basin tally, and would probably be offset by the cost of the
removal of the piles in the slipway.
7
Table information sourced from Hayward Baker Services.
<http://www.haywardbaker.com/services/soil_nail.htm>
8
Assumes 3 nailed slopes of 3:1 and 364.7m of longitudinal slope
Christian Smallwood (0345236) Page 23 of 32
Geotechnical Design Project The Medway Tunnel
Assumed Mv=1.2
0m OD
Mv=1.2
Assumed Mv=0.69
Mv=0.69
Mv=0.6
Assumed Mv=0.6
The total settlement, if left for an infinite amount of time, is defined by the equation:
dh = ∑ h × mv × dθ , where dθ = 6 × ( 9.81× 1.77 )
h mv dθ dh
6.7 1.2 104.1822 837.6249
1.8 0.69 104.1822 129.3943
2.3 0.6 104.1822 143.7714
Total dh 1110.791
Table 13 – Settlement Values
cv t 4Tv
Tv = & Ut =
d 2
π
T Settlement
Tv Ut
(years) (mm)
0.2 0.00 0.06 65.65
0.4 0.01 0.08 92.84
0.6 0.01 0.10 113.71
0.8 0.01 0.12 131.30
1 0.01 0.13 146.80
1.2 0.02 0.14 160.81
1.4 0.02 0.16 173.70
1.6 0.02 0.17 185.69
1.8 0.02 0.18 196.95
2 0.03 0.19 207.61
2.2 0.03 0.20 217.74
2.4 0.03 0.20 227.42
2.6 0.04 0.21 236.71
2.8 0.04 0.22 245.64
3 0.04 0.23 254.26
2.3 0.03 0.20 222.63
Table 14 – Settlement over a period of time
Using this data, the following graph was produced to impose a visual
impression of the settlement over 3 years. Assuming the spoil will be stored on site
for 2.3 years, a maximum settlement of 223 mm is expected.
Settlement vs Time
0.00
0 0.5 1 1.5 2 2.5 3 3.5
-50.00
Settlement (mm)
-100.00
-150.00
-200.00
-250.00
-300.00
Time (yrs)
Qs = ∑ f × pΔ × L
f = α cu
q p = cN c* + q ' N q* + γ BNγ*
B0
φ = 0 → N q* = 1
φ = 0 → N c* = 9
Q p = Aq p = A ( ( 80 × 9 ) + ( 0 × 1) ) = 720 A
To calculate the basic properties of the pile, the skin friction and point bearing
pressure of the pile must first be established. Once they have been established, a pile
length that delivers a loading capacity of 1012kN, which incorporates a factor of
safety of 1.5 for skin friction and 3 for point bearing capacity, can be established. An
assumption has been made that the price per metre of the pile is constant to an infinite
depth, and is proportional to the cross-sectional area of the pile. The assumption has
also been made that there is no critical depth for skin friction. Below is a summarised
table of the results. For the extensive calculation, please consult the spreadsheet on the
attached cd-rom.
As can be seen, the more slender the pile, the cheaper it is. However a
maximum length to depth ratio of 20 has been assumed. With this in mind, the
cheapest pile design is a 0.6 m diameter pile, of 11.74m depth. The total piling for this
crane foundation will cost £2106/pile, or £8424 in total.
Again assuming a maximum value of L/D of 20, here the appropriate choice
would be a pile between 0.4 – 0.45m in diameter, and 8 – 9m in length.
From this table, it can be seen that the cost of a driven pile is considerably
more than an under-reamed pile. However the installation of a driven pile is much
faster, and less prone to accidents.
11. Dewatering
Dewatering is often needed in any large excavation, the reason is obvious: to
prevent the construction area from flooding. A variety of methods exist to free the
site from water, and they are all specific to the nature of the geology of the soil. For
example, sheet piling physically blocks the flow of water, but may be impeded by the
presence of boulders, or whilst a pump drains the water, the pressure may be
insufficient in a granular soil of high permeability. A presence of both may also be
used. Essentially, they work by artificially lowering the level of the phreatic surface
and disturbing the normal flow into the area concerned.
A physical cut off, such as the combi wall used in the Medway tunnel, can be
used in soils of any permeability as an effective long term flooding prevention system.
If the toe penetrates an impermeable layer, then a pump will only be needed to
initially drain the excavated area, and can then be left. However if the strata at the
base of the pile is permeable, then pumps will still be needed during the operation
period. However once the water has initially been cleared, fewer pumps will be
needed to maintain the drawdown.
From the borehole log of the casting basin site, it can be seen that the base of
the combi wall penetrates a chalk layer. This shallow chalk will have a high porosity,
so pumping will be required in addition to the physical cut-off. Due to the significant
depth of the excavation base, at -10.5m OD, wellpoints are not a suitable choice. As
an alternative, deepwells or ejector systems, which have a sufficient depth range, are
the best option9 for the Medway borehole log.
Installation cost (£) Running Cost (£/week) Cost over 2.3 years.
b Pump Feasible?
Min Max Min Max Min Max
Combi-wall Sump No -- -- 120 240 14352 28704
Combi-wall Wellpoint No 2000 5000 250 400 31900 52840
Combi-wall Deep Well Yes 1500 2000 60 105 8676 14558
Combi-wall Ejector System Yes 250 850 500 750 60050 90550
Table 19 – Possible Pumping Systems & costs per pump
The above table gives a summary of the key pumping systems, as well as their
approximate costs per pump. The deep well is by far the cheapest for the period of
time its being employed. However contingency systems have to be put in place for
both the deep well and ejector system, as both require electricity. Contingency pumps
will also be required for maintenance on other pumps, which can quickly become
expensive.
cu 21
CBR = = = 0.913
23% 23%
9
Table 1.3 “summary of principal pumped well groundwater control methods”, Ciria report C515, p
34.
Christian Smallwood (0345236) Page 29 of 32
Geotechnical Design Project The Medway Tunnel
Assuming that a standard HGV has a carrying capacity of 12m3, the number of truck
journeys is:
Excavation 272, 420m3
= = 22, 686
Truck Capacity 12m3
Assuming that a standard HGV has 4 axles, the total number of axles to pass over the
road is:
22,686 x 4
= 90,746.04
= 0.091x106
The most likely threat to materialise is the risk of piping, whereby the water
passes beneath the base of the sheet pile. This can occur when the cofferdam is
founded on relatively permeable material, and flood the area of excavation.
Depending on the circumstances of the soil, there are two ways to avert this. If
the toe of the sheet piles penetrate a stratum of low permeability, such as clay, then no
additional major works need to be done. Once the excavation site has been dewatered
to 1m below the excavation level, then the lowered phreatic surface need only be
monitored. However significant investigation needs to be done to establish whether
Christian Smallwood (0345236) Page 30 of 32
Geotechnical Design Project The Medway Tunnel
there are any sand pockets in the clay stratum, as these will allow the clay pore
pressures to return to hydrostatic pressures more rapidly.
If however the sheets are being installed into a permeable stratum, such as
sand or gravel, then dewatering will not be enough to keep the water table below
excavation level. Additional measures such as anchoring a concrete slab to the
excavation base can be used to seal off the excavation area. Alternatively a water tight
geotextile can be installed below the phreatic surface, and enough ballast sand fill put
on top to counteract the pore water pressure uplift.
In larger sites, such as the one needed for the east and west portal of the
Medway tunnel, more significant measures need to be used to oppose the overturning
force from the hydrostatic pressure of the adjacent river water. The two principle
options are to construct a cellular cofferdam, or to use a double wall cofferdam. Both
act in a similar way: they are effectively a retaining wall against the water.
The base stability is also affected by the lateral hydrostatic pressure. Therefore
the profile of the sheet piling can also play a significant part. For instance, a straight
sheet will be prone to significant bending stresses, where as a corrugated sheet will be
largely more effective. The layout of the excavated area can also have a significant
impact on the effectiveness of countering overturning pressure. For example, an arc
sheet wall will be less likely to collapse in the same way that a cathode ray tube
avoids implosion through having a curved screen.
The cofferdam structure used in the portals of the east and west end of the
tunnel will have had extensive investigation and analysis done prior to the
construction. It will have been designed to a high factor of safety, as the excavation
area is considerably large, and would have been in operation for a significant period
of time. Failure in this case would have been catastrophic!
14. Bibliography
Craig, R.F. (2004), Soil Mechanics, 6th Edition, E & FN Spon
Phear, A., Dew, C., Ozsoy, B., Wharmby, N.J., Judge, J. and Barley, A.D. (2005) Soil
nailing - best practice guidance (C637), CIRIA
Preene, M., Roberts, T.O.L., Powrie, W. and Dyer, M.R. (2000) Groundwater control
- design and practice (C515), CIRIA
The Phi Group (2006) Soil Nailing and Facing Systems, [Online], Available:
http://www.phigroup.co.uk/downloads/soilnailing.pdf (Last accessed: 18/01/2007)
Tomlinson, M.J. (2001) Foundation Design & Construction, 7th Edition, Prentice Hall