Professional Documents
Culture Documents
Luc Maertens*
* Manager Engineering Department Besix, Belgium, lmaertens@besix.com
Associate Professor Catholic University Leuven, luc.maertens@bwk.kuleuven.ac.be
Abstract
The Dabhol Power Company (DPC) is constructing Indias first Liquefied Natural Gas
(LNG) Terminal on a remote strip of the western coast along the Arabian Sea about
160-km south of Mumbai. Designed to handle the largest LNG carriers, the Terminals
marine facilities includes a Jetty that extends 1750-m into open sea to reach adequate
depth, a jetty head supporting the unloading arms and the control tower, four berthing
dolphins, four mooring dolphins, walkway support dolphins, three navigation dolphins
and one tug berth.
473 steel open-end piles (dia.762-mm) support all these structures and are driven into
weathered basalt to support working compression loads up to 4000 kN. Tensile loads
up to 2000 kN are supported by 610-mm diameter sockets that are bored beneath the
pile tip in the underlying basalt.
The subsoil consist of three subsequent layers:
1. Soft clay layer with a thickness varying between 0 and 6-m.
2. Weathered Basalt with a thickness of 1 to 5-ms, and a RQD value varying between
0 to 90%.
3. Sound Basalt with unconfined compression strength varying between 29 and 115
MPa.
A significant problem consists of defining a installation procedure for the piles, which
reconcile the requirement to guarantee an adequate bearing capacity with a risk of
damaging the pile tip, and the requirement of limiting the deformation of the pile tip in
such way that the installation of the socket through the steel open end pile remains
possible without damaging the bore hammer.
An onshore test program was performed to solve this problem.
To confirm the findings of the test program, Dynamic Pile Tests were carried out on
offshore piles. In this way the bearing capacity of the installed piles was controlled.
This paper discusses the test program which was carried out to define the installation
conditions (Hammer Energy and Penetration per blow) in order to guarantee the bearing
capacity in compression and tensile together.
For compression piles, a penetration of 1 mm per blow is required and for tension piles
5 mm per blow for 16 m piles and 2,5 m per blow for 19 m piles is not to exceed
The Marine Works of the Dabhol LNG project were awarded by Enron Engineering and
Construction Company to the Belgian Contractor BESIX as a design and built contract
in December 1997.
The jetty consists of a concrete deck that is supported by prestressed beams. The beams
are supported by bents 30-m apart. Vertical and raked steel open-end piles support the
bents. Every 120-m is a construction joint and in the centre of each section of 120-m is
a strong point bent. Berthing, mooring, navigation and walkway support dolphins as
well as the jetty head are slab-structures supported by the same piles.
Two types of piles are used: piles dia.762, th.16-mm and piles dia.762, th.19-mm. All
piles are provided with toe reinforcement consisting of a 12-mm thick steel plate welded
inside the pile tip. The height of this reinforcement is 380-mm. The length of the piles
varies from 20 to 35 meters and the steel grade is X60 (413 N/mm).
The marine structures are protected from the sea attack by a breakwater of 2300-m
parallel to the shoreline. However, during the first monsoon, the progress of the
breakwater will not be sufficient to give an adequate protection. For this reason all
structures are designed to resist to wave loads with a significant height of 9-m. Other
loads to consider are: a current of 1 m/sec, live loads on the decks and last but not least
an earthquake load with a ground acceleration of 0.16-g. Mooring and berthing
dolphins have to resist to horizontal forces of 6000 kN.
1. Pile Hammer:
The driving hammer used for the installation of the piles is an IHC Hydrohammer S90.
The hammer is hydraulically operated and the weight of the hammer is 92 MN, the
weight of the ram is 45 MN. The hammer has an operating impact energy operation
rate of 2 to 90 kJ.
2. Boring equipment:
The drilling equipment
used in Dabhol is specially
designed and build for the
site by Geotec International
(Belgium) and consists of a
Numa Reversh Circulation
Hammer (Massachusetts,
USA) combined by a RCD
rotary head (NCB, Italy).
It allows for boring a 610m socket in the weathered
and sound basalt trough the
762-m piles.
The
RCDS-3
drilling
equipment consists in (see
figure):
1. Casing clamp
2. Working platform
3. Raking cylinder
4. Mast
inclination
cylinder
5. Rotary head
6. Mast
7. Pull-down
hydraulic
gear motor
8. Suction pipe
9. Drill rod
10. Casing
11. Stabiliser
12. Down-the-hole hammer
10
20
30
40
50
60
70
80
90
100
TCR
DEPTH (m)
RQD
To
perform
the
onshore trial pile test, a
series
of
onshore
borings were carried
out in order to find a
location
with
a
geological
profile
which was as similar
as possible as the
available
offshore
borings. The aim was
to find a location with
a sufficient thick layer
of weathered basalt.
A typical boring at the
test location is given
here beside.
Nine unconfined rock
core
tests
were
performed, giving an
UCS of respectively:
72,5 43,1 61,6
50,8 113,3 52,6
65,1 30.0 and
42,8 MPa
10
15
7000
90 kJ
SRD (kN)
6000
67,5 kJ
5000
45 kJ
TNOWAVE
4000
3000
2000
0
10
20
30
40
50
60
70
80
90
7000
90 kJ
67,5 kJ
SRD (kN)
6000
45 kJ
5000
TNOWAVE
4000
3000
2000
0
20
40
60
80
100
120
140
A pile test up to 8000 kN was performed on pile C2. The pile characteristics are as
follows: The pile with an external diameter of 762-m and a wall thickness of 19-mm
was embedded over a length of 3,28-m. The total length of the pile was 4,40-m.
The ultimate bearing capacity can be calculated from the formula:
Qub = * qub * Ab
with: = installation coefficient = 0,5 for driven open end piles [1]
qub = ultimate bearing pressure
Ab = section of the pile basis = 0,456 m
qub = c * Nc
with: c =
quc =
=
Nc=
cohesion = * quc
unconfined compression test of the rock ( 30 MPa)
0,1 for RQD = 0 70% [2]
bearing factor = 15 for = 35 (= internal angle of friction for
basalt) [3]
10
700
Load (ton)
500
Load
400
Settlement
300
3
200
600
2
100
0
0
100
200
300
400
500
600
700
800
900
1000
1100
1200
1300
1400
0
1500
Time (min)
1000
2000
3000
4000
5000
6000
7000
8000
loading
WORKING LOAD
3
unloading 1
loading 2
unloading 2
6
The bearing capacity was also measured by a local subcontractor, using a dynamic test
procedure together with the well-known CAP-WAP program but unfortunately, the
results were not trustable.
Below gives the driving records for pile C2 together with the interpretation for the
bearing capacity using formula [2] and the not trustable dynamic test results are given.
1,0
3,0
9200
6600
4,0
2000
4000
6000
8000
5,0
10000
Penetration (m)
0,0
Testpiles 762x16mm
Sockets 61mm
9,59
9,60
T1
8,54
T2
8,59
5,95
4,35
1,35
-0,05
250
500
750
1000
1250
1500
1750
2000
0,4
0,5
Unloading
0,6
0,7
0,8
500
1000
1500
2000
2500
0,5
1,5
2,5
Working load
3,5
10
3000
3500
4000
4500
5000
As the tensile capacity of the pile is not only generated by the friction on the socket, but
also by the friction on the steel pile, and since the uplift design is neglecting the last, it
was advisable to split up both. In Figure 17 one can distinguish two slopes in the
loading curve. We assumed that the change in slope corresponds to the start of
mobilisation of the friction on the socket. One can see that it was found that the friction
on the steel pile was 1250 kN or 123 kN/m (= 0,123 MPa).
Results of the tensile test:
Pile
Socket
length
(m)
T1
6.0
T2
3.0
T3
3.0
Working
load
(kN)
2000
1000
1000
Deflection
at working
load (mm)
1.5
0.5
Test load
(kN)
4000
2000
5000
Deflection
at test load
(mm)
2.8
0.7
3.4
Table 1
The mass of mobilised soil can easily be calculated. It is not measured since the
foundations of the reaction supports of the tensile test are inside the influence
core.
(1) (3): Only the sum of both is measured. The split of both is done according to pile
load test T2 figure.
(4):
The length of the socket plug inside the pile was 2,3-m. The bonded surface is
thus :
* 0,73 * 2,3 = 5,3 m
According to BS 5400, the bond stress between the steel pile and the infill
concrete is 0,4 MPa for ULS.
During pull-out test, the bond stress was 0,71 MPa
(1):
The bond stress between the concrete socket and the rock was:
3750 /( * 0,61 * 3) = 0,65 MPa
According to Tomlinson [4] the bond stress is 0,36 MPa in ULS. Under working load, a
bond stress equal to 0,12 MPa was assumed in the design.
Bond stress (MPa)
ULS
Test
Test/ULS
Steel pile concrete
0,4 (*)
0,75
1,8
Concrete socket - rock
0,36
0,65
1,8
(*) according to BS 5400 Part 5 art 11.1.3
11
Damage of pile tip as shown above can not be accepted since excessive damage of pile
tip prevents the installation of the sockets through the piles.
The TNOWAVE analyses as documented in chapter 4 also gives the stress during
driving.
The combination of the SRD, Stress during driving, Hammer Energy and penetration
per blow leads to graphs as given in below for a 16-mm compression pile.
It shows that the stresses during driving, for a same SRD, decrease significantly with
the hammer energy, and increase slightly with the number of blows for a penetration of
100-mm.
12
9000
90 kJ
8000
67,5 kJ
7000
SRD (kN)
6000
5000
45 kJ
4000
3000
2000
1000
0
0
10
20
30
40
50
60
70
80
90
450
Yield stress = 415 MPa
400
350
300
250
200
150
0
10
20
30
40
50
60
70
80
90
On another hand, analysis of the pile toe damage during driving (using the IHC
Hammer at full Energy = 90 KJ), leads to the following conclusions:
Pile
Thickness
(mm)
T1
T2
T3
16
16
19
13
Damage
at toe
(m)
0.1
0.5
0.5
As one can see, the maximum stresses during driving were close to the yield stress
(415 MPa). In fact these maximum driving stresses are computed by the IHC model
with the assumption that the stresses are uniformly distributed over the entire cross
section. This is of course never true in reality, and an appropriate safety factor has to be
used in the definition of the refusal criteria.
Considering the stress analysis in view to guarantee the SRD, together with the damage
analyses leads to the final installation criteria. It was decided to allow 80% of the yield
stress (=332 MPa) for compression piles and 55% (= 225 MPa) for tension piles, since
tension piles need a socket.
Finally the installation procedure was as follows:
Pile
Compression
Tension
(kj)
45
67.5
45
45
(% of full energy)
50
75
50
50
(*) This criterion was checked by installing two additional raking piles on the test
location onshore. After inspection, no damage at pile tip was observed as shown
below.
14
3.
4.
Structure
1
2
3
4
5
Jetty
Approach
Jetty
Approach
Jetty
Approach
Jetty
Approach
Jetty
Approach
Bent
Rake
Loading
Type
Thickn.
(mm)
Ultimate
Resistance
SRD
(hammer
records)
SRD
(dynamic
test)
16
Compression
19
7650
8626
15700
1/3
Compression
19
7650
7693
7935
15
1/3
Tension
19
3825
4767
7140
Tension
19
3825
4654
15950
1/3
Tension
19
3825
4720
8700
Jetty Head
1/3
Tension
19
3825
3780
8970
Jetty Head
1/3
Tension
16
2620
3006
6245
Jetty Head
1/3
Tension
16
2620
3998
6109
Jetty Head
1/3
Tension
16
2620
3147
5650
10
Jetty Head
Tension
16
2620
3398
6085
15
14000
Resistance (kN)
12000
10000
16000
8000
6000
4000
2000
0
1
10
Conclusions
Installation of open end piles in rock (weathered basalt) can be controlled efficiently
under the condition that a continuous controlled hammer is used together with an
adequate pile recorder.
In the case of Dabhol, all hydraulic functions of the IHC-S90-Hammer are
electronically regulated. This ensures optimum control of the energy blow rate and an
optimum control of the penetration of the pile to the required depth without damaging
the pile toe.
This is essential in the case that sockets have to be drilled through the pile toes after
driving. Onshore tests and preliminary calculations allowed for a prediction of the
Ultimate Bearing Capacity in function of the applied Hammer Energy and the
penetration per blow. Offshore dynamic tests confirmed the presumed bearing capacity.
References
[1]
[2]
[3]
[4]
16