Steel Sheet Piling Design Manual

State-of-the-art sheet piling foundation
solutions and their applications
Dr. Pierre-Nicolas Werner

Head of Business Development, ArcelorMittal Commercial RPS
IQPC Piling and Deep Foundations Africa Johannesburg

16th August 2011
Agenda
Introduction to ArcelorMittals state-of-the-art range of foundation solutions

Solutions for transport & urban infrastructure projects
Case study Unterinntalbahn (Brenner) railway line, Austria
Solutions for harbour construction
Case study Jade Weser Port, Germany
Straight web sheet pile solutions
Case study Solis hydroelectric dam, Switzerland
Recent innovation durability example
ArcelorMittal your worldwide one-stop provider of foundation solutions
Johannesburg, 16th August 2011 Piling and Deep Foundations Africa 2011 1
A bit of history
First rolled steel sheet pile in USA: Lackawana type, 1908.

Since 1911, ARBED / ARCELOR / ArcelorMittal have improved sheet pile sections
A bit of history
Types of steel sheet piles 1
U - section
Z - section
Combined wall
Types of steel sheet piles 2
Max. Wx (cm3/m) approximately:

Section modulus Wx per type of
U-type: 3 200 sheet pile solution
Z-type: 5 000
HZM/AZ: 46 500 50 000
46500 45000
45 000
Pipe/AZ: 45 000
40 000
35 000
Applications:
Wx (cm3/m)
30 000
temporary, small excavations / retaining 25 000
structures: 20 000
Wx < 2 500 15 000
marine structures (<12.0m dredge level) / 10 000
5015
deep excavations: 5 000
3200
Wx < 5 000 4800 4000
0
large quay walls / deep cofferdams: U-type Z-type HZM/AZ Pipe/AZ
Wx > 5 000
Hot rolled Z and U type steel sheet piles (2011)
AZ 13 AZ 18 AZ 26 AZ 48
Z type
AZ 13-770 AZ 18-700 AZ 26-700 AZ 38-700N
PU 12 PU 18 PU 22 PU 28 PU 32
GU 7N GU 13-500 GU 16-400
U type
AU 16 AU 20 AU 25
Old range of HZ / AZ (since 1990s)
23
17
1050
462
HZ575 HZ775 HZ975 HZ1050
Combined wall system with 4 sections, 4 thicknesses (A, B, C, D):

Elastic section modulus Wel,y 2 870 32 045 (cm3/m)
Moment of inertia Iy-y up to 1 731 300 (cm4/m)
Steel grades for hot rolled steel sheet piles
EN 10248 ASTM JIS

fyk fyk fyk
fyk [MPa]
[MPa] [ksi] [MPa]
S 240 GP 240
S 270 GP 270 A 328 39 270 SY 295 295
S 320 GP 320
S 355 GP 355 A 572 Gr. 50 50 345
S 390 GP 390 A 572 Gr. 55 55 380 SY 390 390
S 430 GP 430 A 572 Gr. 60 60 415
S 460 AP* 460 A 572 Gr. 65 65 450
Addition of copper 0.35%, 0.50%

ASTM A 690: high strength low alloy steel for use in
marine environments (Gr. 50 and higher available)
Agenda

CASE STUDY
Unterinntalbahn (Brenner) project Austria
Carried out by
Challenges
All retaining walls initially designed in concrete sheet pile combined walls not
previously used in Austria as temporary structure
Proximity to existing (running) railway line and roads, and to buildings
Proximity to river Inn and risk of flooding
Existing groundwater level
Multiple crossing over/under river, roads and existing railway
Multiple construction methods
Conventional tunneling (including under compressed air)
Cut-and-cover method with underwater concreting
Shield tunneling method
Many different cross sections along the 40km track
Driving tests water jetting
tubes
15 25 bar Water
Pump Tank
Driving tests HZ king piles
First temporary use of HZ-AZ combined

wall system in Austria
Driving tests AZ sheet piles
Declutching detection: DIXERAN
If necessary to verify the integrity

of the wall, i.e.:
Detail A
hard driving / obstacles
cut-off walls (environmental jobs)
Protection cap Dixeran: detector to verify the shearing of

Control box a pin
Detail A
Cut & cover building phases 1
Driving of sheet piles
Example of driving plan
HZ-AZ combined walls and PU anchor walls
HZ-AZ combined walls and PU anchor walls
Introduction of sealant use of driving template
PU anchor wall
Dredging works
Underwater works supervised by divers
Anchoring & concreting
Dewatering of trenches
Finishing concreting works after dewatering
Tunnel construction / introduction of tunneling machine
in finished dry trench
Removal of sheet piles for re-use or sale
Temporary sheet pile retaining wall for
safety shaft
Proximity to roads and existing railway
Other major recent transport infrastructure projects
Widening of M1 & M25 motorways, UK
Vienna Metro, Austria
High Speed Line, Netherlands

Examples of sheet piles in permanent use for transport /
urban infrastructure
Congonhas underpass
Sao Paulo Airport, Brazil
Project location
Examples of sheet piles in permanent use for transport /
urban infrastructure
Flood defences
Bridge abutments
Underground
Johannesburg, 16th August 2011 car parksPiling and Deep Foundations Africa 2011 35
Agenda

New range of HZ-M
h t s w
Nb of sections
(mm) (mm) (mm) (mm)
HZ 880 M A, B, C 831 19 - 23 13 - 15 458 - 460

HZ 1080 M A, B, C, D 1075 20 - 30 16 - 19 454 - 457
HZ 1180 M A, B, C, D 1075 - 1087 31 - 37 20 - 22 458 - 460
w/4
w tmax tmax
r t
h h1 y y h y y
h h1 y y s s
s
HZ 880 M HZ 1080 M HZ 1180 M
t = 19, 21, 23 mm t = 20, 23, 26, 30 mm t = 31, 33, 35, 37 mm
New HZ-M production facility
Concept: milling instead of rolling

Two separate milling tools are shaping the groove into the HZ-M flange to enable the threading
of connectors for AZ-infill elements.
Comparison HZ-M / HZ
Standard AZ infill sheets:

AZ13, AZ13-770, AZ18, AZ18-700,
AZ26, AZ26-700
Iy Wel,y * G100%
(cm4/m) (cm3/m) (kg/m2)
HZ 575 A-12/AZ13 96 470 2 870 178

HZ 1050-C23 1 731 300 32 045 705
HZ 880M A-12/AZ 13-770 215 290 4 815 200 + 45%
HZ 1180M D-C23 2 579 400 46 500 992
Combination C23
Combination 12
Performance of new HZ-M range
HZ-M
HZ. 12 & 24
Infill sheet pile: AZ18-700
13 265 18 895
CASE STUDY
Deep Sea Terminal JadeWeserPort
Germany: location of logistic n 1 in Europe

- Present capacities are not sufficient to comply
with increase of cargo handling in near future
Wilhelmshaven: existing navy harbour

- Good transport connection with rails and highway connection
- Natural water depth 18 m
- Economically underdeveloped region
- Close to CT Bremerhaven and Port of Hamburg
Deep Sea Terminal JadeWeserPort
General layout
1.725 km
New access channel
Facilities
Berths: 4
Container cranes: 16 120 ha
Van Carrier: 68
Stacker: 8 170 ha
Train handling cranes: 5
Quay wall cross section
+7,50
30,80 m
-23,30
Construction of the quay wall
with ArcelorMittal sections
HZ1080M A24 / AZ 13 12/12
y y
Infill sheets
AU 20
AZ 13-12/12
Main piles
Anchor piles HZ 975
HTM 600/136 HZ 1080M
Fender piles
D=1219 mm
t=25 mm
Steel piles
D=813 mm
t=17.5 mm
HZ-M Box piles length up to 46 m
Max. rolling length: 33 m

Splicing of HZM
Fabrication of box piles & shaping
Challenge: fabrication / logistics / storage
HZ 1080 M 24
L = 24 48 m
G = 18 up to 46 mt
total 830 box-piles
25 - 30 pieces per week
> 1000 mt / week
delivery plan
Positioning of king piles in template
Driving of main king piles
Jack-up platform and supply barge
Driving of battered anchor piles, double acting hydraulic
hammer guided on a leader
Installation of the infill sheets
AZ 13-12/12, with min. thickness of 12.0 mm

Vibratory hammer
Anchor pile connection to the front wall
Hinged connection
Anchors in corner before start of filling works
Driving tests for HZM king piles
10 load bearing tests: compression
Tension tests for HTM anchor piles
Inclinometers
Strain gauges
Harbour Area before starting
June 2008
27. Mai 2009
November 2008
27. Mai 2009
January 2009
27. Mai 2009
August 2009
December 2009
March 2011
www.jadeweserport.de
Illustration of completed terminal
Agenda

Straight web steel sheet piles AS 500
Width = 500 mm (nominal) Thickness Interlock fyk

web strength min. yield strength
AS 500 [mm] [kN/m] [MPa]
9.5 3000 355
11.0 3500 355
12.0 5000 355
12.5 5500 355
12.7 5500 355
gravity structure
300 mm L 500 mm
deep wharfs / quays / breakwaters / cofferdams
testing: EN10248-1
structures founded on bedrock
no anchors
Types of cells
Circular cells
junction pile
Diaphragm cells
CASE STUDY
Solis hydroelectric dam, Switzerland
Looking for a solution 1
Looking for a solution 2
Original design complex double-walled sheet pile
cofferdam with 6 levels of struts
After optimisation
Section along cofferdam
Max. sheet pile Gravel backfill

length 30.5m
Lake bed
Silty lake sediments
~ 20-24
g ~ 19-21 kN/m3
Rock line Splicing to add 6m of

length + grouting
528 sheet piles (AS500-9.5 and AS500-12) with a total tonnage of 859 kt were delivered.
A logistical challenge
Spreader beam
with attachment
for handling of
long piles
Putting into place the circular template
Installation
junction pile
After backfilling and drainage
Next step reuse of sheet piles and conversion from
temporary to permanent cofferdam!
Seo-Hae Grand Bridge, South Korea
Tug-boat quay in Paraso, Panama Canal
AS 500-12.0
20 circular cells
= 15.0 m, L = 18.5 20.0 m
3000 t
Circular Cell Structure
E-METHANEX Berth, Damietta, Egypt
Diaphragm Cell Structure
Essar Quay wall, Hazira, India
Agenda

Durability of steel structures
corrosion in undisturbed natural soils is negligible (exception peat, )

in common fresh water, corrosion is low
in sea water, corrosion has to be considered (splash zone, low water)
reference for loss of steel thickness: Table 4.1 & 4.2, EN 1993-5 (2007)
design life (years) 5 25 50 75 100

undisturbed natural soils
0.00 0.30 0.60 0.90 1.20
(sand, clay, )
common fresh water:
0.15 0.55 0.90 1.15 1.40
waterline
sea water: permanent
0.25 0.90 1.75 2.60 3.50
immersion & intertidal
sea water: splash & low
0.55 1.90 3.75 5.60 7.50
water zone
Introducing AM LoCor
Johannesburg, 16th August 2011 Piling and Deep Foundations Africa 2011 84 84
Agenda

ArcelorMittal Sheet Piling Foundation Solutions
extensive engineering pool & technical assistance

team for external interventions
provide regular in-house training for internal and

external technical sales force
elaborate adequate design software & update

technical documentation (PHB,)
provide educational training programs for engineers

at universities, consultants and contractors
leading participation for EC standards, NASSPA,

Chinese Standard Institute, Brazilian Standard Institute
for the construction industry
ArcelorMittal Sheet Piling Foundation Solutions
develop sheet pile technology with R&D as well as with

external institutes
driving tests before validation of new sections or to

confirm project choice and jobsite assistance if
required
close cooperation with driving equipment

manufacturers
provide accessories as for example tie-rods, coating,

sealants, driving caps, steel fabrication works and offer
them as a package together with the sheet piles,
tubular piles and bearing piles
use stocks (new and second-hand), offer rental

contracts and buy-back options
Supply Chain Management: just-in-time deliveries

Thank you
for your attention
http://www.arcelormittal.com/sheetpiling
http://www.arcelormittal.com/projects

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State-of-the-art sheet piling foundation

solutions and their applications

Dr. Pierre-Nicolas Werner

IQPC Piling and Deep Foundations Africa Johannesburg

Introduction to ArcelorMittals state-of-the-art range of foundation solutions

First rolled steel sheet pile in USA: Lackawana type, 1908.

Max. Wx (cm3/m) approximately:

HZ575 HZ775 HZ975 HZ1050

Combined wall system with 4 sections, 4 thicknesses (A, B, C, D):

EN 10248 ASTM JIS

Addition of copper 0.35%, 0.50%

Introduction to ArcelorMittals state-of-the-art range of foundation solutions

First temporary use of HZ-AZ combined

If necessary to verify the integrity

Protection cap Dixeran: detector to verify the shearing of

Widening of M1 & M25 motorways, UK

Vienna Metro, Austria

High Speed Line, Netherlands

Introduction to ArcelorMittals state-of-the-art range of foundation solutions

HZ 880 M A, B, C 831 19 - 23 13 - 15 458 - 460

HZ 880 M HZ 1080 M HZ 1180 M

t = 19, 21, 23 mm t = 20, 23, 26, 30 mm t = 31, 33, 35, 37 mm

Concept: milling instead of rolling

Standard AZ infill sheets:

HZ 575 A-12/AZ13 96 470 2 870 178

Germany: location of logistic n 1 in Europe

Wilhelmshaven: existing navy harbour

HZ1080M A24 / AZ 13 12/12

Max. rolling length: 33 m

AZ 13-12/12, with min. thickness of 12.0 mm

10 load bearing tests: compression

27. Mai 2009

27. Mai 2009

27. Mai 2009

Introduction to ArcelorMittals state-of-the-art range of foundation solutions

Width = 500 mm (nominal) Thickness Interlock fyk

12.0 5000 355

12.5 5500 355

12.7 5500 355

Max. sheet pile Gravel backfill

Rock line Splicing to add 6m of

Introduction to ArcelorMittals state-of-the-art range of foundation solutions

corrosion in undisturbed natural soils is negligible (exception peat, )

design life (years) 5 25 50 75 100

Introduction to ArcelorMittals state-of-the-art range of foundation solutions

extensive engineering pool & technical assistance

provide regular in-house training for internal and

elaborate adequate design software & update

provide educational training programs for engineers

leading participation for EC standards, NASSPA,

develop sheet pile technology with R&D as well as with

driving tests before validation of new sections or to

close cooperation with driving equipment

provide accessories as for example tie-rods, coating,

use stocks (new and second-hand), offer rental

Supply Chain Management: just-in-time deliveries

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