Gunite

a portfolio
piling anchoring grouting guniting allied civil engineering

Kendleas Limited trading as
PJ Edwards & Co. UK.
For enquiries please contact Dublin oce.
info@pjedwards.ie
p: 00 353 (0)1 6268 329
f: 00 353 (0)1 6260 340
www.pjedwards.ie
Edwards Arabia
PO Box 3117,
Al-Khobar 31952,
Kingdom of Saudi Arabia
email: john@edwards-arabia.com
or sulaiman@edwards-arabia.com
p: (+966) 5068 68741
f: (+966) 3894 1199
www.edwards-arabia.com
PJ Edwards & Company Limited
Kennelsfort Road
Palmerston
Dublin 20, Ireland
info@pjedwards.ie
www.pjedwards.ie
p: 00 353 (0)1 6268 329
f: 00 353 (0)1 6260 340
PJE have set up a Piling division in Saudi Arabia based in Al-Khobar in the Eastern
Province. This branch of the company has been constituted as a Joint Venture
company with Dowairah Construction.
The portfolio of works presented in this brochure illustrates works carried out by
our Companies in Ireland and the UK.
We are now in a position to carry out similar contracts with Dowairah Construction
in Saudi Arabia, who will provide logistical support for our Piling Crews who
will be led by our highly trained Irish personnel to ensure a high quality
installation.
4 www.edwards-arabia.com
Any method of installing a column within the ground to carry
a load can be described as piling. Te methods employed
are generally driving, boring and jacking, and the various
subdivisions of these are innumerable.
We have concentrated on developing bored piling techniques
and principally on CFA and ODEX piling methods. Our
CFA piling accounts for most of our piling works. We can
install CFA piles in the range 350-1200mm diameter and up
to 30 metres in depth.
All our piling rigs are dedicated CFA machines built by
Llamada in Spain. It is our opinion that these are the best rigs
available on the market today and a large part of our success
in competing with rotary rig type piling contracts is due to
the capabilities of Llamada piling rigs. Such is our success
with these rigs that we can out-perform rotary rigs on most
contracts in both price and programme.
Our next choice of piling is ODEX piling. Tis method is
used in very dicult drilling conditions where large boulders
exist and/or deep rock sockets are required. Te range of pile
sizes we provide are 150 to 640mm diameter. Te borehole
is drilled using a down-the-hole-hammer and a specially
designed bit that pulls the casing with it as the hole is
advanced. On completion the bit is retracted and the casing
is left in the ground. Generally the casing is withdrawan
once the pile reinforcement and concrete is placed. In some
applications the casing is left in place or partially withdrawn,
e.g. marine works, or in very soft ground.
We also carry out the following types of piling:
a) Bottom driven 220mm diameter piling
b) TRM cast-iron ductile driven piling
c) Displacement piling
d) Hollow stem self-bore piling
Piling
Since its rst use 150 years ago, the practice of injecting grout into voids
in stonework or soil has developed into a technique with many wide uses.
In civil engineering today, this technique is used:-
(i) to strengthen defective structural masonary, e.g. old stone
buildings, masonary arch bridges etc.
(ii) to consolidate or reduce water seepage through a mass of rock
using an ordinary cement grout or a mixture of cement and
clay.
(iii) to increase bearing capacity or reduce settlement in granular
soil deposits.
(iv) to construct a watertight curtain or cut-o in a permeable stra-
tum, e.g. around a reservoir or below a dam structure.
(v) to underpin defective foundations of existing structures show
ing excessive settlement.
(vi) to ll cavity walls of existing buildings to provide a re break.
Rock & Ground Anchoring
Grouting
Tis process has developed considerably in recent years, especially with the advent of hollow stem self drilling type anchorages. Using
this drilling technique, the drill rods are grouted into the soil or rock and left in-situ to become the anchor. Tis has made the instal-
lation process very fast, and in most instances the additional material cost is outweighed by the time savings achieved.
Anchors are typically used to support retaining walls and as anti-otation support for basements and other submersed structures. Tey
are often used for holding down tall light structures such as windmills, pylons etc.
Gunite is the name given to mortar or concrete projected at
high velocity onto a surface. Te fresh material is compacted
by the force of the jet impacting on the surface. It is
frequently more economical than conventional concrete,
since less formwork is generally required, and it forms an
excellent bond on most materials.
It has consistent waterproong properties, even in
thin sections, and admixtures can be used to ensure
permeability.
General uses of gunite include the following:-
(i) New structures, particularly curved or folded
sections.
(ii) Coatings to brickwork, concrete, rock or steel
for protection appearance or waterproong,
e.g. contiguous bored pile walls.
(iii) Encasement of structural steel for re-proof
ing and strengthening.
(iv) Strengthening of masonary walls or arches,
or of deteriorated concrete structures, such
as, buildings, bridges, culverts, reservoirs or
dams.
(v) Stabilisation or reinstatement of sea walls or
fractured rock faces.
Guniting
Soil nailing has become very popular over the past two decades
especially in embankment stabilisation works on motorways and railway
embankments. It is especially useful for sites with dicult access as the
drilling and grouting equipment is typically small and light.
Te hollow stem self drill type anchors / soil nails are very popular as they
are exceptionally quick and easy to install.
Soil Nailing
Introduction
info@edwards-arabia.com
5
Contents
Piling 06
Rock & Ground Anchors 23
Soil Nailing 26
Marine 28
Grouting 35
CFA PILING
PJ Edwards & Co Ltd:
Continuous Flight Auger (CFA) Piling System
General
Since their introduction some seventy years ago in North America, continuous ight auger (CFA) piles, have become
increasingly popular, as they can be considerably more economical than alternative pile types. CFA piles are now com-
monly used throughout Europe and are particularly popular in the UK and Ireland where they account for about 70% of
the piling market. With proper planning and design, powerful equipment and experienced personnel, very high produc-
tion rates can be achieved. Piles are available in any size but typically in 300, 450, 600, 750, 900, 1050 and 1200mm
diameter. Tey can be constructed to depths in a single pass of up to 30 metres.
CFA Equipment
Te equipment normally comprises of:
a base machine with a xed, hanging or swinging leader. Modern machines are generally purpose built CFA rigs.
an auger drive unit with sucient power to advance the continuous ight auger to the required depth with minimum
decompression of the surrounding soil.
continuous ight augers of the required length and diameter (small or large stem), equipped with auger cutting heads
suitable for the material to be penetrated.
on board computer for ensuring quality assurance in constructing pile shaft.
P. J. Edwards and Co. Ltd. use this method of piling for the following piling projects;
Bearing piling from 350mm to 1200mm diameter piles
Secant piling from 450mm to 1200mm diameter piles
Contiguous piling from 350mm to 1200mm diameter piles
King post piling from 350mm to 1200mm diameter piling
7
Installation process
CFA piles are formed by drilling a continuous ight auger into
the ground. Te sides of the hole are supported at all times by
the soil-lled auger, eliminating the need for temporary casing or
bentonite slurry.
Upon reaching the required depth, concrete is pumped down the
hollow stem as the auger is steadily withdrawn. Reinforcement is
placed immediately after withdrawal of the auger into the uid
concrete.
Te bearing capacity and settlement behavior of CFA piles is to a
large extent inuenced by the equipment used. For optimum pile
performance the more powerful the rig the better. Over-ighting
can occur when using under-powered rigs.
Casting of pile base and shaft
When the auger has reached the required depth, the temporary
plug (usually of plastic or steel caps), which prevents soil from
entering the hollow stem, has to be ejected. Tis is accomplished
by slightly lifting the auger and injection of the concrete. A pre-
charged volume of concrete is pumped to the base of the pile be-
fore extraction of the auger begins.
When the concrete head is established, extraction is commenced
at a rate, consistent with concrete supply. Positive rotation of the
auger is necessary to retain the drilling spoil. Te concrete over-
supply must be maintained and the auger must be extracted at a
rate consistent with concrete oversupply and ground conditions.
Te onboard computer gives real time information to the rig driv-
er to assure correct construction of the pile shaft.
Placing of reinforcement
Te reinforcement is installed after the auger has been withdrawn
and while the concrete is still uid. Te placement of a long re-
inforcement cage into an uncased hole requires care so that no
contamination of the concrete shaft is caused with eroded soil.
Terefore, it is important that the cage is sti and properly weld-
ed/tied in order to overcome this problem.
Advantages
Te CFA pile is essentially a non-displacement bored type pile.
Hence, there is little risk of damage to adjacent foundations or
underground utilities from ground displacement or densication
of loose sands, as can occur with displacement piles.
Another advantage is that CFA piles are installed with little vibra-
tion or noise. Should problems occur during pile construction, it
is relatively simple to re-drill and install the pile at the same loca-
tion, thereby eliminating the need to redesign the pile group or
the pile caps.
Te use of onboard computers provides the piling contractor and
the client with excellent information on the strength of the soil
bored and the pile construction ( refer typical computer log at-
tached ). Tese logs give great assurance to clients that the CFA
piling works have been carried out in accordance with best current
practice.
Tere is no need for drill casings or changing of drill tools during
boring of pile. Terefore there is no manual or crane handling
required or the need for vibrators to install or extract casings.
Most importantly CFA piling is very fast and therefore the most
economic way to install bored piles today. Due to developments
in powerful dedicated rigs and computer aided construction CFA
piling has become the most popular bored piling system in the UK
and Ireland and has replaced Rotary piling on most large building
and civil engineering projects in this region.
Aviva Stadium, Lansdowne Road, Dublin
Te Aviva Stadium is a sporting stadium located in Dublin, Ireland, with a capacity for 51,700
spectators (all seated).
Te stadium, set in the midst of Dublins streets and built on the site of the old Lansdowne Road
venue, which was demolished in March 2007, and replaces that stadium as home to its chief ten-
ants: the Irish rugby union team and the Republic of Ireland national football team. Previously
called Lansdowne Road Stadium, the recently renovated Aviva Stadium is the oldest international
stadium in the world.
Te stadium, located adjacent to Lansdowne Road railway station, ocially opened on 14 May
2010. Te stadium is Irelands rst, and only, UEFA Elite Stadium and in 2011, it will host the
Europa League Final. It will also host the inaugural 4 Associations Tournament, as well as the
regular home xtures of the national rugby team and national football team from August 2010
onwards.
In designing the 50,000-seat sports park Populous and Scott Tallon Walker Architects sought to
minimize the structures environmental footprint as much as possible. Te sweeping roof of the sta-
dium does double duty in terms of green features its constructed from sturdy transparent materi-
als that shelter the interior while allowing daylight to seep in, and it harvests rainwater to irrigate
the sports eld. Te north end of the stadium features a smooth slope that dips to allow daylight
to reach nearby residences, and a smart set of ecient xtures conserve energy for instance, the
escalators only operate when people are standing on them.
Everything about Aviva Stadium, from its architecture to its environmentally friendly design, has
been inspired by the best ideas around the world to create a truly innovative sporting venue.
In 2007, Dublins famous Lansdowne Road stadium (then the worlds oldest international rugby stadium) was demolished to make way for the
construction of a new stadium that would take Irelands national soccer and rugby teams into a home t for the 21st century.
9
Specialist services:
PJ Edwards were engaged by BAM Contractors to carry out the piling works as
part of the enabling works package.
A total of 1468 No. 350, 450, 600 & 750mm CFA bearing piles with SWL of 750-
4000kN were installed.
All piles were founded at depths between 6-12m into the underlying limestone
bedrock.
The works also included double corrosion protected permanent holding down
anchors to support the stadium roof.
Spencer Dock, Dublin
Before its current urban regeneration Spencer Dock was a 51 acre browneld site located on the
North side of the Dublin Docklands.
Te site was developed by its owners, the Spencer Dock Development Company (SDDC) who,
along with the Dublin Docklands Development Authority, aimed to transform the Dublin Dock-
lands into a world class city quarter.
We were very privilaged to be involved in many of the building projects on the site which included
residential blocks (RSTUV), commercial buildings (block C) and the very striking National Con-
vention Centre which opened in late 2010.
Our works on the site included secant piling on block C and the National Convention Centre
(known to native Dubliners as the Tube in the Cube), including capping beams and tie-back an-
chors, and bearing piles on the above sites and blocks RSTUV.
On blocks RSTUV piling outputs were the biggest ever achieved by this company with 350-500
cubic metres of pile concrete placed daily.
Client: Spencer Dock
Development Company
Location: Dublin City Docklands
Contractor: CMP Limited
Engineer: OConnor Sutton Cronin
11
After forty months of development and construction, and over a decade of planning wrangles and debate, Irelands rst purpose-built
conference centre has opened. Announced as the worlds rst carbon neutral convention centre, it is the rst Irish building designed by
Pritzker Prize-winning and Irish-born architect Kevin Roche.
Te Convention Centre Dublin features a unique glass atrium, which encompass the full height of the building and oers visitors an
opportunity to experience Dublin with extensive views across the skyline, bay and Dublin Mountains. Te building is congured to
accommodate conferences from 8 to 8,000 participants in 22 purpose-built meeting rooms. It includes a 2,000-seat auditorium, 4,500
square metres of exhibition space and banqueting facilities for up to 5,000 guests.
Te centre combines exible and elegant conference halls and meeting spaces with an extensive range of support services. Te Convention
Centre Dublin announced it is the rst carbon neutral international convention centre as the net impact of the buildings construction on
the environment is zero. Tis landmark, can be considered carbon neutral due to the use of low carbon cement throughout the building
and through osetting all unavoidable carbon emissions by investing in carbon credits in accordance with the Voluntary Carbon Standards
(VCS).
National Convention Centre
In summary the works on these sites included:
1009 No 900mm secant piles 14-19 metres deep
2680 No 600, 900, 1050 & 1200mm bearing piles 10-17 metres deep
67 No 900mm contiguous piles 11 metres deep
26 No 119mm TRM ductile cast iron piles
545 metres of guide wall
281 metres of capping & waling beams
229 No temporary & permanent ground anchors
The above works total value exceeded 8 million.
Static load test on 1200mm CFA pile, proof load = 16,500kN
Corrib Natural Gas Terminal
Client: Shell Exploration & Production Ireland Limited
Project Manager: PM Group Limited
Engineer: AMEC
Location: Bellanaboy, Co. Mayo
Te Corrib Field was discovered in 1996 by Enterprise Energy Ireland Ltd, which was subsequently
acquired by Shell E&P Ireland Limited (SEPIL) in 2002.
Te Corrib Gas Partners are Shell E&P Ireland Limited, Statoil Exploration (Ireland) Limited and
Vermilion Energy.
Tere are four main components to the Corrib gas project; they include the oshore sub-sea infra-
structure at the Corrib eld, the oshore pipeline, the onshore pipeline and the onshore gas-process-
ing terminal located at Bellanaboy Bridge in County Mayo.
Overview
Early stages of works. PJ Edwards piling rig can be seen in the background.
13
Natural gas consists principally of methane and is often found together with water or other hy-
drocarbon gas and liquids. Gas in the Corrib eld is a dry gas containing only small quantities of
liquids, which will be removed at the terminal at Bellanaboy Bridge.
Te main purpose of the terminal is to process and dry the gas by removing liquids so that it is
suitable to ow into the Bord Gis Eireann (BGE) pipeline network. Located 9 kilometres inland
near Bellanaboy Bridge, Co. Mayo, the terminal is being constructed in a wooded area so as to
cause minimum visual impact to the surrounding area. It has been designed to process up to 10
million standard cubic metres of sales gas per day and will be operated 24 hours a day.
The Gas Terminal
PJE installed 1430 No. piles for Bellanaboy Gas Terminal at Bangor-Eirs, Co.
Mayo.
A small number of piles were drilled at a rake using ODEX piles with permanent
liners.
The vast majority of the piles were 450mm diameter CFA bored piles installed
using high torque Llamada rigs which allowed us to drill over 5.0 metres into
Georges Quay, Dublin
Whilst the piling works on this site were technically unchallenging it is one of those contracts that
we nd very pleasing to be associated with.
Te building is visually very striking and has a fantastic location overlooking the River Liey.
Client: Cosgrave Homes
Contractor: G&T Crampton
Engineer:
The piling works involved the installation of 473 No. 600mm CFA
bearing piles founded on limestone rock, with a SWL of 2000kN.
The rig used on this site was a Llamada P90 CFA rig.
15
Criminal Courts of Justice, Dublin
Name: Dublin Criminal Courts of Justice
Contractor: P.J. Hegarty & Co Ltd
Engineer: ARUP Consulting
Te impressive new Criminal Courts Building is located in the west side of Dublin City,
close to Phoenix Park, where its elevated location gives it a striking position looking down
on Dublin City to the East below.
Te tricky part on the site was not associated with piling in dicult ground but avoiding
old bombs dating back to World War 2! Te site had previously been used as an armaments
factory.
Our works on site involved contiguous piling, bearing piling, and tie-
back anchorages.
Using a powerful Llamada P150 CFA rig with torque of 27tm,
we installed 600 & 900mm dia. piles 1-2 metres into underlying
limestone rock.
Trinity Biosciences, University of Dublin (Trinity College)
Tis facility which is due to open in 2011 will accomodate Trinitys Institute of Immu-
nology, a Centre of Excellence in Cancer Drug Discovery, Institute of Neuroscience and
Trinitys Bioengineering Centre. Its opening will coincide with the tercentenary of medical
education in 2011. Te build will accomodate around 1,000 researchers by 2013.
Our involvement in the project arose from the requirement for a triple basement for this
building. We designed and constructed a 900mm diameter hard/sti secant pile wall with
pile lengths up to 19m deep to provide a retained height of 10m. Te length of wall in-
stalled is 309m.
Te geology of this site is generally 4m of made ground over 3m of sandy gravels over 8-
12m of boulder clay over limestone rock. As you can see from the arial photograph the
loading conditions on three sides of the site are HA loading but on the remaining bound-
ary we have the old masonry Pearse Street railway station.
Client: Trinity College Dublin
Contractor: Walls Construction
Soil nailing the existing rail platform retaining wall above the new secant pile wall
17
Mater Hospital, Dublin
Client: MCHD
Contractor: P.J. Hegarty & Co Ltd
P.J. Hegarty & Co Ltd were awarded the enabling works package for the new Childrens Hospital.
Te package of works included for the demolition of existing buildings, the construction of the site
perimeter retaining walls, and the bulk excavation of the site.
We were awarded the pile wall sub-contract which included the design & construction of 520
metres of a 900mm diameter hard sti secant pile wall and all associated works which included
construction of guide wall, capping beams, tie-back anchors and anchor reactions.
Strand Road, Portmarnock
Client: Carrickhill Developments
Engineer: Byrne Looby & Partners
Our works on this project included for the design & installation of
an anchored secant pile wall and the provision of 640 & 900mm
diameter bearing piles within the single level basement.
On this project PJ Edwards & Co Ltd were the main contractor
responsible for all aspects of the basement works excluding the ex-
cavation itself. PJE had responsibility for setting out, construction
of guide walls, installation of secant and bearing piles, anchoring
of secant pile wall and monitoring of same.
Te project included 408 secant piles and 75 bearing piles.
Clancy Quay, Dublin
Te Clancy Quay residential development is sited on the old
Clancy Barracks on the West side of Dublin adjacent to Heuston
Station. Te barracks has been associated with various military
events, including the Crimean War, the Boer War, World War 1
and the 1916 Easter Rising.
Tis sizeable project included secant piling, contiguous piling,
bearing piles, tension piles, and tie-back anchors, along with con-
struction of guide walls, waling beams, diagonal braces and also
design and monitoring of all the constituent parts.
Drilling conditions on site were very onerous due to the presence
of very large boulders within dense gravel overlying very sti
boulder clay. Despite the dicult ground conditions, our powerful
P150 Llamada rigs delivered the works within programme.
Te project included:
678 No. 900mm diameter secant piles
23 No. 600mm diameter secant piles
129 No. 600mm diameter contiguous piles
188 No. 600mm diameter bearing piles
79 No. Tie-back anchors
143 No. Tension piles
www.edwards-arabia.com 19
Dublin Airport Terminal 2
ODEX PILING
Over the past few years Dublin Airport has had a number of mod-
ications and extensions to Terminal 1. Te DAA announced in
August 2006 that it planned to build a new 395m terminal at
Dublin Airport capable of handling up to 15m passengers per
year.
2010 saw the opening of Terminal 2 which is a very modern and
impressive gateway for airline passengers into and out of Dublin.
At its peak, Terminal 2 was the largest construction project in the
state, and employed up to 2,600 workers on site. During three
years of construction, more than 10,400 men and women were
involved in the project and more than 1,000 new jobs will be cre-
ated with the opening of the new terminal.
Terminal 2 will be home to Aer Lingus, American Airlines, Continental Airlines, Delta Air Lines, Etihad Airways and US Airways.
We were awarded the piling subcontract to provide foundation bearing piles for the adjoining Terminal 2 car park.
Te works comprised the installation of 342 ODEX / CFA 640 & 900mm dia. rock socketed piles to give SWL of 2500-4125kN.
Indaver Waste to Energy Facility M50 / N3 Interchange
Indaver are building a waste-to-energy facility in Duleek Co. Meath. Te development is valued at
130,000,000 and represents the largest ever single investment in solid waste management infra-
structure in Ireland.
Our association with the project involved secant piling for the waste bunker and turbine cellar, and
foundation bearing piles for the waste bunker administration building, the furnace boiler area, the
steam condensate cycle, turbine & generator build-
ings.
A total of 868 rock socketed piles using ODEX / CFA
piling methods were installed. Te secant pile walls
were built using 600mm diameter hard/soft piles
founded up to 5 metres into rock.
Te bearing piles consisted of 450mm diameter &
600mm diameter ODEX/CFA pileswith SWL of
1000kN and 2000kN respectively and rock socket
lengths of 1-2 metres.
Tis project involved the building of a very complex interchange between the N3 and the M50
motorway and complicated further by the fact that some piers had to be constructed between the
existing railway and canal and the busy M50.
Due to limited access these piers had to be founded on mini-piles incorporating large tension &
compression loads. Te pile design also required the provision of permanent steel liners to each
pile.
Te ODEX piling method proved ideal in meeting this requirement and the need to install deep
rock sockets.
Casagrande CFA26 piling rig predrilling 640mm diameter
ODEX rock sockets.
21
Wyattville Bridge
Owing to the increase in trac from the M50 into Dun Laoighaire
and the increase of urban development in South County Dublin,
the interchange at Wyattville was upgraded. Tis interchange fa-
cilitates a trac ow of 50,000 vehicles a day and is the second
busiest section of motorway in Ireland.
Te new Wyattville overbridge runs East to West over the N11
South Eastern motorway. Te overbridge consists of two piled
cast-in-situ concrete abutments with a similarly constructed cen-
tral pier carrying 30 metre long precast concreted bridge beams.
We were contracted by Jons Civil Engineering Ltd to install 640mm
diameter ODEX cased rock socketed piles to carry the two abut-
ments and central pier. A total of 114 No. 640mm ODEX piles
were installed to an overall average depth of 26 metres including
an average rock socket of 4 metres.
Phase 1 of this project, carried out in 2007, required the construction of a
triple basement with a retained height of 13.5 metres. Over most of the site
the rock level within the basement was 3 to 4 metres above formation level.
Our proposed solution was to provide a secant pile wall with 900mm CFA
sti piles and 640mm ODEX hard piles at 1.0 metre centres.
Te 900mm diameter CFA piles were nominally socketed into rock and the ODEX 640mm piles were drilled 4 to 8 metres into intact
rock. Te pile wall was restrained by two levels of tie-back anchors.
Phase 2 works were carried out in 2010. Te scope of works was considerably smaller than Phase 1 and included:
secant piles as described above and 450mm & 600mm diameter CFA bearing piles with SWLs of 1400 & 2200kN respectively. Both
phases included the construction of guide walls, capping beams and both permanent and temporary tie-back anchors.
Portlaoise Shopping Centre
Client: Lindat Ltd
Contractor: Harcourt Construction Limited
Engineer: OConnor Sutton Cronin
23
ROCK & GROUND ANCHORS
Berth 50 Extension
Te works are the extension landward of the existing Berth 50 within Dublin Port by
50 metres to provide additional berthing capacity within a load-on, load-o container
handling/shipping facility.
We were sub-contracted by BAM to install 58 No. 40 metre long permanent double
corrosion protected rock anchors with working loads up to 1200kN.
Client: Dublin Port Company Limited
Contractor: BAM Civil Engineering Limited
Engineer: Jacobs Engineering Limited
Te works on this project involved the upgrading of the existing mooring & berthing dolphins on the Exxon jetty. To enhance the dolphins capacities,
selected dolphin legs were loaded to increase their capacity using permanent prestressed anchors installed into the bedrock some 20 50 metres below
the dolphins platforms.
Anchors up to 75 metres in length were installed, making them amongst the longest anchors ever installed in the British Isles.
Te anchor capacity required was 1200 1525kN per anchor. Te anchors used were 8 11 No. Multistrand 15.2mm Dyform tendons with double
corrosion protected in accordance with BS8081.
Braefoot Bay Oil Loading Jetty, Scotland
Client: Exxon Shell
Contractor: Balfour Beatty
Construction (Scotland)
25
Wanlip Water Reclamation Works
As part of an expansion to the existing works we were contracted to design and install permanent
400kN anti-otation ground anchors for the newly constructed storm water tank, aeration tank
& the nal settlement tanks on this site.
Client: Severn Trent Water
Contractor: Taylor Woodrow
Location: Leicester, England
Tis large project required the provision of 832 anchors with an average length of 20 metres.
Te anchors were founded in keuper marl interlayed with skerrie bands.
Te deeply sloping conical nal settlement tanks presented an interesting challenge as can be noted
from the photos.
Anchor being homed in position
SOIL NAILING
A 12 metre stretch of masonry retaining wall 1.7 metres high and the embankment above it col-
lapsed onto the adjacent Vico Road which resulted in the road being closed for a period of time.
Te original solution was to rebuild a reinforced concrete retaining wall and to temporarily support
the embankment with soil nails to allow construction of the new wall.
An obvious improvement to this design was to simply reprole the retaining wall and embankment
using permanent soil nails and and facing the front of the soil nail wall with masonry and the em-
bankment with soil and shrubs to match in with the original.
Vico Road, Dalkey
Balvac Whitley Moran Ltd were contracted to remediate the existing masonry retaining wall. Te
works involved raking out and repointing the entire wall, grouting up behind the wall and installing
9 metre long double corrosion protected soil nails.
PJ Edwards & Co UK were sub-contracted to carry out the soil nailing works. On completion of the
soil nailing we grit-blasted the old blackened masonry wall to reveal a very pretty sandstone beneath
as the photograph shows.
Mount Street, Rochdale, England
27
Bray Head
Tese works which we carried out as main contractor involved
the stabilisation of the earth embankment over the cli face
above the Bray to Greystones railway line between tunnels 3 &
4 at Bray head.
As the railway remained live during the remedial works, all work
had to be carried out at night. Given the very dicult access,
practically all of our operations were carried out from a hanging
platform suspended from a large crawler crane.
Soil nailing at Quilty, County Clare
Shotcreting at Dock Road, Limerick
Malahide Viaduct
Te causeway supporting the pier foundations for the railway viaduct had been sub-
jected to several programmes of grouting. Te work specication was prepared by
C.I.E. and a constant check had to be kept on the grout levels during injection, to
ensure a sucient spread was being maintained in the strata below the viaduct.
Each span and pier was rst dried out by placing a purpose made sheet pile dam across
two of the piers, the sheet piles being driven into the seabed on each occasion. Tis al-
lowed drilling and installation of the grout pipes to take place in reasonably dry surface
conditions.
Te exercise was carried out in the 1950s, 60s & 70s to prevent scouring of the river
bed, and undermining of the viaduct foundations by tidal ow in the bay.
Joseph Edwards supervised these earlier works during his time with Cementation Lim-
ited and lately for PJ Edwards & Co Ltd.
MARINE WORK
29
Malahide Viaduct
In August 2009 one of the viaduct piers collaped due to severe scouring in the causeway. A passenger
train had just passed over when the train driver witnessed the collapse behind him. Due to his imme-
diate emergency response, he prevented a certain catasrophe had the next train reached the viaduct.
Emergency works were required to repair the causeway, rebuild the collapsed peir and decking and
upgrade the remaining existing piers through underpinning. Te works were designed by Irish
Rail.
PJ Edwards & Co Ltd were engaged to carry out the underpinning of the existing piers by mini-
piling using 51 & 76mm hollow stem self-drilling piling techniques. Tese piles were drilled to
depths of up to 18.5 metres through the existing stone lled causeway, typically 6 metres deep
overlying 6 metres of silt, overlying very sti boulder clay.
Each pile required coring a 150mm corehole through the existing ashlar limestone masonry pier and
installing a 135mm diameter permanent casing into the causeway. Te silt below the causeway was
then pregrouted below the casing for a depth of 2.5 metres before the pile was nally installed.
A typical pile arrangement in shown in Diagram 1 overleaf.
Client: Irish Rail
Contractor: Jons Civil Engineering Limited
Diagram 1
31
Cootehall Marina
Over the years we have been involved in several of these type of projects. Te oating landing
stages are kept in position using either driven or bored steel tubular piles normally 300 400mm
in diameter. In dicult driving conditions when sti boulder clay or rock is encountered, ODEX
piling methods are popular.
Te ODEX drill rigs are ideally suited for working on oating platforms or pontoons.
We have carried out numerous similar projects along the River Shannon.
Rosslare Pier, Wexford
An examination of the pier foundations revealed that the lower foundations had subsided in
places, due to the scouring action produced by the propellors of ships using the piers. Te reme-
dial work proposed had two functions, namely, to stabilise the pier in its present condition, and,
secondly, to prevent any recurrence of the problem.
As shown in the sketch to the left, the remedial work involved driving sheet piles along the area
aected by the scouring action, to prevent any further scouring of the seabed below the pier. Te
piles were driven to bedrock, some 30 feet below low water level and the tops of these xed to the
pier wall with 25mm tie rods. Te gap between the piles and pier wall was lled with 3 aggregate.
Colgrout was injected and regular checks kept to conrm that the grout was spreading evenly and
rising through the hardcore at a reasonable rate.
When the colcrete had reached the required level, the piles were trimmed and capped by the cli-
ent. Exploratory drill holes through the pier deck into the foundations proved that the voids had
been successfully lled.
33
Rosslare Pier continued...
Te bow-thrusters used in modern type ocean going vessels in order to push o the pier cause quite a lot of turbulence
underwater. Tis turbulence in turn caused undermining along a considerable length of the old boat pier at Rosslare
Harbour. In some cases the cavaties were up to two metres high and four metres deep, hence it was only a matter of
time before the whole structure was seriously endangered.
It was felt that sheet piling and grouting as had been used earlier (see opposite) would have been unsuitable in this
case. Consequently, it was decided to inject a colloidal grout of sand and cement into purpose built @Fabriform Bags@
within the cavaties. A diver was employed to prepare the cavaties and to place the bags which were held in place by
xing 100x100 mesh ush with the face of the pier. Grouting pipes were xed onto the bags in order to faciliatate sec-
ondary grouting of the inll at the rear of siad bags. Afterwards boreholes were drilled through the outer leaf of the pier,
through the @Fabriform Bags@ and into the rock underneath. Tese boreholes were lled up with grout and twelve
metre long steel bars were then dropped into same in order to pin the bags into position.
Te design and specication for this work was prepared jointly by C.I.E. and PJ Edwards & Co Ltd, and successfully
carried out during the o season (winter).
Ballycotton Pier, Cork
Te breakwater wall is constructed with large at concrete blocks, laid horizontally and mortar
jointed.
Over the years the wall foundations had been undermined locally resulting in partial collapse and
leaving large holes through the wall.
Fabriform Bags were inserted in the wall cavaties and lled with grout under pressure. Divers as-
sisted in this work, some of which was below low water level. Complete sealing was ensured by sec-
ondary drilling and grouting through the grouted Fabriform Bags and into the existing wall.
Some patchwork guniting was carried out to repair small sections elsewhere on the wall.
www.edwards-arabia.com 35
GROUTING
Dunnes Stores, Cork
Contractor: John Sisk & Son Ltd
Tis project was nearing completion when a change of layout
in the building required the relocation of a travelator pit to be
opened in the basement slab.
Te problem was that the basement is located in highly perme-
able coarse gravels adjacent to the River Lee, and 5 metres below
same. Not a job for the faint hearted.
Note the fountain eect in the photo when a hole was punctured
through the basement slab.
Te adopted solution to control the inow of water to the trave-
lator pit was to construct a grout matress which would render
the pit excavation impermeable (permissable inow was < 4
litres/second).
Primary grouting was carried out by injecting cement & ben-
tonite grout through drill lances, and secondary grouting was
carried out by injecting sodium silicate, grouted via tube--man-
chette. Te photographs show the grout injection locations, the
hydraulic drill rig over a primary hole location with grout being
injected, and workmen within the travelator pit excavation con-
structing the new pit slab and walls.
Queen Elizabeth II Bridge
Te Queen Elizabeth Bridge and the two road tunnels are collectively
known as the Dartford Crossing which connects Dartford in the South to
Turrock in the North on the M25 London orbital motorway. Te rst
tunnel was built in 1963 and the second in 1980. Te bridge was com-
pleted in 1991.
Tis cable stayed bridge is 137 metres high with a main span of 450 metres.
Te piers carrying the main span are each founded on a caisson constructed
of reinforced concrete. Te two caissons were constructed in Holland and
towed from there to their destination where they were sunk into position
on a prepared stone bed. Te caissons, when positioned, were lled with
concrete.
Our contract was to grout the void between the underside of the oor
of each caisson and the stone bed on which each caisson was founded.
A 300mm perimeter projection on the underside of the caisson bedded
into the stone bed under the weight of the concrete lled caisson. It was
expected that the perimeter projection would penetrate the stone bed by
100-200mm, leaving a gap of 100-200mm under the caisson. To provide
full passive restraint for the pier in the event of it being struck by a ship the
void was grouted using a sand-cement-PFA grout.
To facilitate grout injection the internal walls of the caisson were tted with
vertical 50mm steel pipes for injection and egress of grout. Given the large
area to be lled with grout, the original idea was to compartmentalise the
underside of the caisson by grouting into grout socks tted to the underside
of the caisson oor. When lled, the socks would form internal barriers
under the oor and each compartment could be grouted in a controlled
manner. Unfortunately, the socks didnt work and were subsequently aban-
doned. Tis resulted in round the clock continuous grout injection until
the void was fully lled.
A total of 785 tonnes of sand-cement-PFA grout was used to ll the void
under both caissons.
37
St. Patricks Bridge, Cork
Tis famous bridge in the centre of Cork City, built in 1859, had been showing signs of settlement over the crowns and
other visible signs of distress such as spalling of the arch rings at the quarter points etc. for some time.
Because of its strategic importance, it was decided to place a reinforced concrete saddle over the arches in order to
prevent any further decline in the structure. Cork Corporation themselves carried out this work.
In conjunction with the above mentioned work it was decided to pressure grout the foundations because:
(a) Of increased bearing pressure on the footings
(b) It was possible that earlier settlements had emanated from weaknesses in said foundations
Tis entailed drilling down vertically through the piers and abutments through the supporting caissons and some three
metres into the underlying materials (some 12 metres depth overall) using a track mounted crawlair drill. Specially
fabricated self sealing tremie pipes were then driven into said boreholes and a very thin mix of neat cement together with
an intrusion aid was injected into the sub-base under very high pressures.
Te foundations and piers of a number of other bridges were grouted in a similar manner in order to cater for increased
loading due to reinforced concrete saddles and/or cantilevered footpaths for road widening purposes.
Arklow Bridge, Wicklow
Te existing structure is a 19 arch masonry bridge, which was widened with a reinforced concrete structure carried on in-
situ bored piles.
Te masonry has shown deterioration over a long period and we were awarded the contract for repairs, including the follow-
ing:-
(1) Complete grouting of foundations, piers and arches of spans 14 to 19 inclusive. Arches 16 to 19 were strengthened
with 150mm of gunite with a double layer of 50x50mm 10G mesh, and arches 14 & 15 received
75mm of gunite. Additional works included placing of tie-rods and buttress plates in above arches.
(2) Arches 1 to 13 inclusive; foundations and piers were grouted and the arch sots covered with a 30mm coat of gu-
nite.
All work was carried out with the co-operation of Wicklow County Council.
39
Beaufort Bridge, Kerry
Beaufort Bridge spans the River Laune on the road leading to the world famous Gap of Dunloe of Kate Kearney renown.
It is a very long bridge consisting of 13 rubble masonry arches many of which were showing signs of deterioraton to a
varying degree.
Te whole bridge was grouted having rst applied a spraycoating of gunite to the arch sots in order to seal the joints
and prevent the egress of grout.
Load relieving gunite arches were applied to some of the more seriously defective arches and tie-bars were installed in
arches where there was evidence of bulging.
Listowel Bridge, Kerry
Tis most striking bridge spanning the River Feale at Listowel consists of ve seg-
mental arches built with ashlar masonry. Due to excessive lateral thrust in the abut-
ment at the end the internal spandrel walls moved a little. Tis in turn caused set-
tlement of the arch sots, the eect being most pronounced on the end span (c. 6
settlement at the crown).
In order to arrest the settlement and prevent any further deterioration of the structure
it was decided to grout the bridge.
Having won the contract we carried out the grouting work using a cement grout mix.
Sand was added to the mix to reduce costs wherever possible. After grouting opera-
tions were completed the bridge was cleaned down using sandblasting. No further
evidence of settlement has been noted since.
41
Glanmire Bridge, Cork
Tis bridge had a restricted loading, and bulging, cracks and open joints were evident in all three arches. An assessment of the
bridge showed a safe working axle load of only 3.5 tons. A 100mm layer of gunite was applied to the two outher arches and a
150mm layer to the middle arch. All three arches and foundations were grouted. Using the same assessment this brought the
working axle load to 10.5 tons. To date, these repairs show no sign of new distress.
Incidently, this bridge was overgrown with vegetation which was removed at the same time as above, and has thus far re-
mained remarkably free of any new growth.
Ballyforan Bridge, Galway
Tis masonry arch bridge spans the river Suck at Bally-
foran, and was in need of urgent repair. Extensive reme-
dial works were carried out by this company involving
guniting, grouting and transverse tieing of the bridge.
Some 555 boreholes were drilled into the arch structure,
piers and foundations and neat cement grout injected
therein.
52 no. 20/25mm diameter H.T. tie-rods with butress
plates were installed. A 50mm singly reinforced layer of
gunite was placed to each of the 13 arch sots.
43
Shannonbridge, Offaly/Roscommon
Tis elegant bridge crosses the River Shannon at Shannonbridge. It boasts 16 masonry arches plus
what was once an opening steel truss deck. Te opening section was replaced, and it was decided to
strengthen the entire bridge in conjunction with the reconstruction work. We undertook this latter
work as sub-contractors.
Te piers of the bridge were grouted with neat cement grout from a level of 1 metre below the
foundation abseto the arch springing level. Te joints in the exposed faces of the piers, arch span-
drel walls and parapet walls were neatly pointed with a 1:3 cement-sand plasticised mortar from
low summer water level to the parapet capping stones.
Dislodged parapet stones were re-bedded. Te sots of the arches were gunited to springing level
with singly reinforced 50mm gunite.
Millicent Bridge, Kildare
Tis is a 6 arch masonry bridge on a secondary road, with spans of approximately 19 ft. Tree arches on the north
side were in distress with arches misshapen and trees and shrubs growing out of the masonry of the piers and abut-
ments.
Another contractor constructed a coerdm and strengthened the lower portion of piers and abutments with re-
inforce concrete walsls. An R.C. apron was laid on the river bed under each arch. Tey also repaired and pointed
defective masonry joints.
In conjunction with the main contractor, we grouted the foundations and also inll of piers, abutments and arches.
Additionally a 50mm thick load relieving arch of gunite, reinforced with a single layer of 50x50x10swg weldmesh
reinforcement was placed under the arches.
Te remianing three arches on the south side were similarly treated.
45
Edwards Arabia
has shown here a sample of the contract work carried out by our Irish &
UK Companies in recent years.
We have built up considerable expertise in many aspects of geotechnical
engineering, and continue to monitor new developments in this eld all
over the world.
We offer a full service involving site investigations, recommendations,
design and construct options especially in relation to Piling and Anchoring,
where we have built up an unrivalled store of knowledge pertaining to all
conditions and obstacles likely to be encountered.
If you have a civil engineering problem and feel that we can be of assistance
to you in any way, we will be delighted to hear from you. Advice costs
nothing more than a telephone call or a quick email.
Contact
Edwards Arabia
PO Box 3117, Al-Khobar 31952, Kingdom of Saudi Arabia
t: (+966) 5068 68741
f: (+966) 3894 1199
We wish to thank our many Clients, their Consulting Engineers and Main
Contractors with whom we have had the pleasure or working, and whose
projects we have featured in the various sections of this booklet.
Contact
Edwards Arabia
PO Box 3117, Al-Khobar 31952, Kingdom of Saudi Arabia
t: (+966) 5068 68741
f: (+966) 3894 1199
Kendleas Ltd trading as
PJ Edwards & Co UK.
For UK enquiries, please
contact our Dublin office.
Edwards Arabia
PO Box 3117
Al-Khobar 31952,
Kingdom of Saudi Arabia
t: (+966) 506868741
f: (+966) 38941199
john@edwards-arabia.com
sulaiman@edwards-arabia.com
PJ Edwards & Co Ltd
Kennelsfort Road
Palmerstown
Dublin 20, Ireland
t:+353(0)1 626 8329
f:+353(0)1 626 0340
info@pjedwards.ie

Gunite

Diunggah oleh

Informasi Dokumen

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

Gunite

Diunggah oleh

Hak Cipta:

Format Tersedia

a portfolio

piling anchoring grouting guniting allied civil engineering

Anda mungkin juga menyukai