German University in Cairo

Faculty of Engineering and Material Science

Civil Engineering Program
Heavy Civil Construction
Winter 2014 / 15

CIG 704: Heavy Civil Construction

Final Exam [150]

1. Explain the main characteristics that differentiate heavy civil construction from building
construction. [12]

Building Construction includes residential housing (single-family & multi-story and high-rise
buildings) as well as commercial building projects (schools and universities, hospitals,
stadiums, large shopping centers, warehouses and skyscrapers for offices and hotels).
The required engineering expertise is not as sophisticated as in heavy civil projects;
investments into equipment technology is less which attracts a high number of contractors
and makes the market highly competitive.
In comparison to residential housing, the institutional and commercial building projects
exhibit higher costs and greater sophistication. This market is shared by fewer competitors.
Owners of commercial projects are investors who usually select competent professional
consultants to manage the project. Projects are normally financed by institutional
lenders.
Heavy Civil Construction projects include highways, railways, tunnels, bridges, airports,
seaports, pipelines, drainage systems and sewage treatment plants.
The project volumes can be very significant and most of these projects are publicly owned
and financed through tax monies.
This category of construction is technology-driven and highly mechanized, with use of
massive equipment which requires significant investments. This limits the number of
contractors who can perform such projects. Other resources like construction materials are
significant and material provision needs to be diligently planned for.
The consultants and contractors engaged in infrastructure projects are usually highly
specialized.

Prof. Dr.-Ing. Mahmoud El Khafif Final Exam WS 2014 / 15, Page [2]
 German University in Cairo
Faculty of Engineering and Material Science
Civil Engineering Program
Heavy Civil Construction
Winter 2014 / 15

2. Heavy Civil Construction projects are often resource-driven. Name the main project
resources, explain their significance for the implementation schedule and propose measures
to mitigate the shortage of these resources. [12]

Resources for the Implementation of the Project (local or off-shore)

• Staff and Labor: required in the right qualification, number and on time
• Materials: cut-and-fill materials, crushed rock for roads and structures, bitumen,
cement, steel, cables, aluminum, glass etc.
• Equipment: earth moving, structure concrete, road construction, lifting etc.
• Sub-Contractors and Suppliers: for all trades
• Funds: liquidity is the lifeline for all site operations, a positive cash-flow for the project
is the desired case.
Resource planning is based on the project implementation schedule. Any delay in provision of
required resources will automatically reflected on the project performance and might
jeopardize the interim milestones or the project completion date.
Mitigation measures include a careful and realistic planning when which resources are
required, involving which funds and keeping reasonable reserves in the overall planning. A
back-up scenario is always beneficial to simulate and provide for the case that a major delay
happens (sometimes caused by 3rd parties).

3. Describe the bridge construction method with ”Movable Scaffolding” and make a sketch to
show the components of the equipment and demonstrate how the method works. [14]

This system is typically used for long bridges with repetitive spans. The curvature is limited
and spans should be of regular length (35-45m).
The system is based on the vertical support of the formwork through the permanent sub-
structure of the bridge. Loads from fresh concrete and form-work itself are directly
transferred to the bridge pier into the foundation. As the system does not require ground
support for load transfer it can be used over deep valleys, for water crossings and over traffic.
Material supply comes from the abutments side via the completed sections.
The length of the underslung truss is > 2 x span. The section that carries the fresh concrete
loads being of heavier made while front and back sections which only serve for traveling the

Prof. Dr.-Ing. Mahmoud El Khafif Final Exam WS 2014 / 15, Page [3]
 German University in Cairo
Faculty of Engineering and Material Science
Civil Engineering Program
Heavy Civil Construction
Winter 2014 / 15

truss are lighter structures. For dismantling, the truss travels into the next span and the
formwork follows in its new position.

The picture shows the formwork spanning between two piers, supported by the heavy middle
section of the truss which is resting through steel cross beams on the piers of the permanent
substructure(without ground support). Also shown are the lighter front and end sections of
the truss. These are used to move the heavy middle section and the formwork into the
working position in the next span.

4. Make a sketch showing the main components of the “Incremental Launching Method” for
bridge construction. Explain the process steps of this bridge construction method.
What is the principle difference between the “Movable Scaffolding Method” and the
Incremental Launching Method”? [8+12+4=24]

Prof. Dr.-Ing. Mahmoud El Khafif Final Exam WS 2014 / 15, Page [4]
 German University in Cairo
Faculty of Engineering and Material Science
Civil Engineering Program
Heavy Civil Construction
Winter 2014 / 15

The process steps are as follows:

a) Establishment of the field factory to cast the superstructure sections (casting bed),
including foundation works, formwork, shed and launching station with hydraulic jacks,
b) Casting, curing and post-tensioning of the superstructure section,
c) Moving the bridge superstructure section by hydraulic jacks into the first span position,
thus evacuating the casting bed for the next section,
d) Installing the launching nose at the front end of the first section,
e) Repetition of the casting and launching steps, sliding of the superstructure over the
bearings at the pier heads using PTFE plates until the front end reaches the opposite
abutment,
f) De-installation of the field factory, casting bed and launching nose.

The main difference of both bridge construction methods is that the “Movable Scaffolding” is
an in-situ concrete solution with works taking place at different span locations and at height
while the “Incremental Launching” is a pre-cast solution with a stationary factory, protected
from weather and at grade.

5. In tunneling with Tunnel Boring Machines (TBM), the two main technologies (1) “Earth
Pressure Balanced (EPB) Shield” and (2) “Slurry-Shield” are applied. Explain the main
difference between applicability of both technologies regarding the soil characteristics in
which the tunnel is to be built and the way of excavation material transport.
Explain the “Mix Shield Technology” [4+4+4=12]

 TBM with Earth Pressure Balance (EPB) Shield, the first choice in cohesive soils with high clay
and silt contents and low water permeability. Soil, excavated by the cutter head is conveyed
by srew conveyor and conveyor belt to the rear end of the tunnel.
 TBM with Slurry-Shield, earth and water pressure are balanced by slurry. The cutter head
excavates the soil while mixing it with slurry. The material is then conveyed hydraulically in
pipes to the rear end of the tunnel.
 The Mixshield technology is an advance on conventional slurry technology. The support
pressure in the excavation chamber is precisely managed using an automatically controlled
air cushion. This means that heterogeneous geologies and high water pressures of more than
15 bar can be controlled safely even with very large diameters.

Prof. Dr.-Ing. Mahmoud El Khafif Final Exam WS 2014 / 15, Page [5]
 German University in Cairo
Faculty of Engineering and Material Science
Civil Engineering Program
Heavy Civil Construction
Winter 2014 / 15

6. Explain three measures to increase the load bearing capacity of bored piles and reduce
settlements. [3x4=12]

Measures to reduce settlements resp. to increase the pile load bearing capacity
With pile foundations next to built-up areas sensitive to settlement the adjacent settlements
must be minimized by the deformation of the piles. The same applies if the settlement
difference of adjacent foundations is restricted. On the other hand the measures to increase
the load bearing capacity can reduce the pile diameter and / or the pile length.
a) Increasing the pile diameter and / or increasing the pile length
With the increase of the pile diameter the point pressure is reduced by the order of two and
the shaft friction raises linear to the increase. The settlements can be reduced.
b) Shaft grouting
With shaft grouting, the shaft friction is increased by additional selective injections into the
pile shaft area. For this purpose a thin plastic tube with valve is attached to the rebar cage
for each injection point. When the pile concrete starts hardening the
concrete cover of the valves is blasted with water high pressure and subsequently injected
with cement slurry. On blasting the concrete cover of the rebar cage is partially shifted
against the soil. The gap is „cured“ by cement slurry, so that the
concrete steel is secured against corrosion.
c) Pile base grouting
During pile base grouting a pressure bag, a pressure bubble or a pressure box at the bottom
of the rebar cage is injected with cement slurry by an injection tube after construction of the
piles. This measure extends the pile base injection facility and therefore causes a preload of
the soil under the pile base (anticipation of the settlement) before the building load is placed.
d) „Additional“ shaft grouting
For the rehabilitation of bored piles with a non-sufficient load bearing capacity it is possible
to carry out injection drillings around the piles and to inject grout. This corresponds to a pile
cross-section enlargement and increases the load bearing capacity.
e) Pile base enlargement
For mainly base bearing piles a pile base enlargement for increasing the load bearing
capacity can be recommended.

Prof. Dr.-Ing. Mahmoud El Khafif Final Exam WS 2014 / 15, Page [6]
 German University in Cairo
Faculty of Engineering and Material Science
Civil Engineering Program
Heavy Civil Construction
Winter 2014 / 15

7. List and briefly explain 5 selection criteria for the various trenchless tunneling methods. [10]
Diameter Range: The range of diameters for which the trenchless construction method can
install a pipe.
Drive length: The maximum length of a drive that is possible for a particular trenchless
construction method.
Work space requirements: This is further described by the workspace size, the need for a
shaft/pit whether it is a driving or receiving shaft and the need for installation of thrust
blocks within the pit.
Soil Conditions: Describe the favorable and unfavorable soil conditions for a particular
trenchless construction method.
Productivity Range: Describe the expected advance rate for a particular trenchless
construction method. This rate depends on the soil conditions, pipe diameter, required
accuracy and drive length.
Cost Range: Describes the expected cost for using a trenchless construction method that is
usually a function of pipe diameter, soil conditions and drive length.
Obstacle detection: Describes the ability of the TCM to detect obstacles that might be
encountered during advancement.
Accuracy: The tolerance of the installation trenchless construction method. This attribute is
most pertinent in congested areas and during long drives. The actual accuracy of any
particular technique will depend on the surrounding soil conditions and the drive length.

Prof. Dr.-Ing. Mahmoud El Khafif Final Exam WS 2014 / 15, Page [7]
 German University in Cairo
Faculty of Engineering and Material Science
Civil Engineering Program
Heavy Civil Construction
Winter 2014 / 15

8. List and briefly explain four main safety measures to be considered during the construction of cast-in-
situ box girders of a bridge span. What is the meaning of PPE? [14]
PPE: Personal Protective Equipment
Working at height:
Avoid working at height if possible
Use work equipment suitable for the task i.e. Scaffold, Mobile tower.
Use work equipment that will minimize the distance and consequences of a fall. i.e.
Air bags, landing mats,
Ladders must be used for short duration work only, tied at both ends.
Do not use step ladders
Scaffolding:
Keep the work platform clear of clutter that could cause tripping hazards
Do NOT work on scaffolds that are covered with ice/snow
Only use approved scaffolds
Do NOT overload scaffolds. This can lead to collapse
Where people are required to work or pass under scaffolds, install a screen of half-
inch mesh between the toe-board and guard rail.
Use diagonal bracing on all support components (never climb or stand on bracing)
Use ladders to enter and exit the scaffold
Materials Handling and Storage
Work practices
Ergonomic principles (fit the job to the person)
Training and education

Fall Protection for Mobile Equipment

Consider the application, then select the appropriate lift.

Check tire condition and inflation
Only use lifts that have passed inspection
Remember that wind conditions aloft may differ from those on the ground
Survey the area for hazards prior to each day’s work.

Prof. Dr.-Ing. Mahmoud El Khafif Final Exam WS 2014 / 15, Page [8]
 German University in Cairo
Faculty of Engineering and Material Science
Civil Engineering Program
Heavy Civil Construction
Winter 2014 / 15

9. A retaining wall shall be constructed (see figure below). The retaining wall is divided into 15
segments, each 10m long. [26]
You are required to make the following:
a. Establish a Work Breakdown Structure (WBS) reaching the activity level.
b. Based on the activities above, establish a Logic Diagram.
c. Estimate the duration of the construction of 1 segment of the retaining wall.
Information given:
a. Assume a steel reinforcement content of 140kg/m3 concrete. The width of backfilling behind
the retaining wall can be assumed with 12m. After construction of the retaining wall an
insulation layer shall be applied. The filter package shall be installed together with the
backfilling (see below figure).
b. Consider that :
i. Ideal productivity of 1 crew of shuttering formwork is 4 m2/h (efficiency factor 0.7)
ii. Ideal productivity of 1 crew of reinforcement steel fixing is 2 t/h (efficiency factor 0.7)
iii. Ideal productivity of 1 crew of pouring concrete is 4 m3/h (efficiency factor 0.7)
iv. Ideal productivity of excavation including leveling and compaction is 10 m3/h. (efficiency
factor 0.6)
v. Ideal productivity of backfilling in layers and compaction: 20 m3/h (efficiency factor 0.6)
vi. Ideal productivity of insulation is 6 m2/h (efficiency factor 0.6)
Make reasonable assumptions for missing information (if required with a short justification).

Prof. Dr.-Ing. Mahmoud El Khafif Final Exam WS 2014 / 15, Page [9]
 German University in Cairo
Faculty of Engineering and Material Science
Civil Engineering Program
Heavy Civil Construction
Winter 2014 / 15

a. Establish a Work Breakdown Structure (WBS) reaching the activity level.

Prof. Dr.-Ing. Mahmoud El Khafif Final Exam WS 2014 / 15, Page [10]
 German University in Cairo
Faculty of Engineering and Material Science
Civil Engineering Program
Heavy Civil Construction
Winter 2014 / 15

Prof. Dr.-Ing. Mahmoud El Khafif Final Exam WS 2014 / 15, Page [11]
 German University in Cairo
Faculty of Engineering and Material Science
Civil Engineering Program
Heavy Civil Construction
Winter 2014 / 15

b. Based on the activities above, establish a Logic Diagram.

Site preparation  SP
Sub-Structure  Sub-S
Super –Structure  Super-S
Backfilling  BF

SP F.S Sub- F.S Super- F.S BF

1 S1 S1 1
F.S F.S F.S F.S

F.S Sub- F.S Super- F.S BF

SP
1 S2 S2 2

And all the inner relations are also Finish to start.

Prof. Dr.-Ing. Mahmoud El Khafif Final Exam WS 2014 / 15, Page [12]
 German University in Cairo
Faculty of Engineering and Material Science
Civil Engineering Program
Heavy Civil Construction
Winter 2014 / 15

c. Estimate the duration of the construction of 1 segment of the retaining wall.

1. Pouring Concrete:
Quantity = (0.5*7*10)+(0.5*7*0.7*10)+(1*4*10) = 99.5 m 3

Duration =

2. Steel Reinforcement:
Quantity = 99.5 * 140 = 13,930 Kg = 13.93 tons

Duration =

3. Shuttering formwork:
Quantity = (2*7*10)+((4-1.2)*10)+(1*2*10) = 188 m2

Duration =

4. Excavation:
Quantity = (4 *2*10)+(.5*2*2*2*10) = 120 m3

Duration =

5. Backfilling:
Quantity = (120-(4*2*10))+(12*10*6) = 760 m3

Duration =

6. Insulation:
Quantity = (7+1.4+1+1+1.4+1) *10 =128 m2

Duration =

Total Duration of 1 segment = 5 + 2 + 9 + 3 + 8 + 5 = 32 days

Prof. Dr.-Ing. Mahmoud El Khafif Final Exam WS 2014 / 15, Page [13]
 German University in Cairo
Faculty of Engineering and Material Science
Civil Engineering Program
Heavy Civil Construction
Winter 2014 / 15

10. In relation to modern role of GPS in Heavy Civil Construction, answer (a) and (b). [6+3x2=12]

a. Give a brief description, along with simple labeled sketch explaining briefly the concept of
how GPS is used in structural health monitoring.
GPS can provide precise (mm level) continuous monitoring of the movements of large
structures, e.g. large dams, long bridges and high-rise buildings. A network of two or more
GPS receivers may be used to monitor a structure movement, using differential GPS (DGPS),
with at least one GPS receivers positioned away from the structure on stable ground, to
provide mm. level accuracy (x,y,z). DGPS observed movements of the structure provides
information on the structure health regarding; structure integrity, durability and reliability.

Prof. Dr.-Ing. Mahmoud El Khafif Final Exam WS 2014 / 15, Page [14]
 German University in Cairo
Faculty of Engineering and Material Science
Civil Engineering Program
Heavy Civil Construction
Winter 2014 / 15

b. GPS role in construction site monitoring is in relation to:

(i) construction worker performance assessment,
(ii) construction fleet management and
(iii) improving construction site security.

State briefly one benefits for each, in presence of GPS.

For “construction worker performance assessment “ any one of the following benefits:
• know exactly which employee operated which vehicle, and the vehicle's hours of
operation
• analysis of the driving and operating behavior of employees
• access control: only licensed and approved drivers operate machines or construction
equipment
• employee timesheets
For “construction fleet management“ any one of the following benefits:
• manage maintenance schedules
• remotely diagnose and monitor equipment systems
• improve fuel efficiency and reduce carbon footprint
• record machine use
For “improving construction site security“ any one of the following benefits:
• protect assets from theft and loss
• help prevent fuel theft
• stop machine, vehicle, and equipment theft
• eliminate unauthorized use of machinery

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