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Top-Down Construction Method: A Case Study of Commercial Building in

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Conference Paper · May 2018

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Seyed Hossein Zargar S.Mostafa Mirmohamadi

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 Top-Down Construction Method: A Case Study of Commercial
Building in Tehran

Seyed Hossein Zargar 1, Seyed Mostafa Mirmohammadi 2

1- Master student in Architectural Technology, University of Tehran
2- Master student in Project Management, University of Tehran
zargar323@ut.ac.ir

Abstract
Today's World is considered the world of new technologies. The impact of science on world-class
technologies can be hardly ignored. Problems and constraints have always been on the way to human
beings, and these problems have contributed to the progress of human knowledge. The construction
industry is not an exception, and there have always been many problems for the industry's engineers and
architects due to various issues such as climatic conditions, environmental conditions, soil condition, and
so on; Therefore, the relevant experts have always tried to provide new and effective methods for solving
them. One of these new methods is the Top Down Construction Method. Top Down refers to the
construction of the main structural members of the building from top to bottom; It is contrary to the
common construction methods so that the construction starts from the ground level and ultimately leads
to the foundation. In this research, we introduce and explain a specific method based on Top-Down and
analyze its implementation in a real project in Tehran.
Keywords: Top-down, Construction Methods, Construction in Iran, Berm

1. INTRODUCTION

Foundation is considered as the most important structural element of the building, which is divided into
different types according to the environmental conditions, bedding, soil type, building use and its importance.
In most common construction methods, construction steps are followed from the bottom up, and the
construction begins with excavation after ensuring the strength of the site and proceeds with the
implementation of the structure and architecture. Although these methods are simple in terms of design and
construction, they change the usual rules in some structures, due to certain conditions or, in other words,
some restrictions including time, place, legal, etc.; Top Down is the result of one such problem.
Top-Down Construction Method is defined for projects where peripheral problems and factors prevent
the construction in the usual way, and consequently, the timing of the project is increased. This method leads
to significant time savings in projects. As the name implies, in this method, the structure of the building,
including beams, ceilings, walls, etc., runs from top to bottom after placing the columns on the pile cages.
Eventually, the top-down structure is connected to the main building foundation after reaching the foundation
level. The factors considered in the excavation include implementation safety, the stability of adjacent
buildings and prevention of their vertical displacements, reduction of the stabilization costs, increasing the
implementation speed, not violating the neighbors' privacy, ensuring system performance, monitoring deep
displacements and eventually preventing the loss of dirt. These factors are accurately and accurately
calculated and controlled during the implementation. In this method, the structural elements of soil inhibitor
are optimally designed and utilized using geotechnical numerical software that is able to analyze the
interaction of soil and structure, as well as structural software and importing the results of the previous
analysis stage to these software applications. For example, the top-down construction method has been used
in the Ban Residential Commercial Complex. This project with an area of 3327 square meters was located
near the main square of the city, surrounded by commercial and residential buildings. The engineers involved
in the construction project considered Top Down as the most suitable method for the implementation of piles,
columns, and perimeter walls so that the impact of the excavation on the adjacent buildings is minimized [1]
The Boston Post Office Parking Project is also another example this new construction method in recent
decades. Parking with capacity of 1500 cars including 7 basement floors, which needed approximately 22-
meter drilling. Top-Down Construction Method was chosen because excavation had no effect on adjacent
buildings [2].

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2. TECHNICAL DESCRIPTIONS OF A SPECIFIC METHOD FOR IMPLEMENTING THE TOP-
DOWN STRUCTURE

In the design proposed in this study, the main structural columns with different spacing between each
other are used as a retaining trench system, and the retaining wall with horizontal steel elements (lateral
beams) play the role of the permanent stabilization system. The Top Down Construction method generally
includes the followings:
1- Well under the main columns
2- Pile Cage
3- Area of the column connected to the pile
4- Columns
5- Horizontal beams between the columns in the vicinity of the soil
6- Retaining wall reinforcement
7- Concreting of the wall
8- Main structural beams
In addition to the above, depending on the circumstances of each project, special steps are added to this
method. In the following, we will explain each of the above:
2.1. Well under main columns:
The first step of this construction method is to drill wells under the main columns. The drilling of these
wells is carried out prior to the excavation and continues to a depth below the foundation level. The cross-
section of these wells can be circular or square according to the design requirement. The diameter and depth
of these wells are accurately determined by calculations and analysis of the project. In the case of soil
sensitivity and specific project conditions, the well drilling can be carried out in stages.(Figure 1)

Place of
wells

Ground level

Foundation
level

Figure 1. The place of wells

2.2. Pile Cage:

After drilling wells under the main columns, the pile cages are placed in an area of wells - the area below
the foundation level. In general, it can be said that these piles act as a temporary foundation for the columns
until being integrated with the main foundation. The size and number of pile cage rebar are determined from
numerical calculations, depending on the excavation depth, the mechanical characteristics of the soil, the
diameter of well and etc.
Concreting of the piles is done in two steps: the first step up to the baseplate level, and the second step is
up to the foundation level. The distance between these two levels is the buried depth of the columns, derived
from numerical modeling. This Concreting should be done with a Tremie pipe in compliance with the 9 th
chapter of the national building regulations. The cement content and concrete strength are also determined
based on the calculations.(Figure 2)

2
 Foundation
level

Concreting of the
piles, 2nd step

Pile cage
Concreting of the
piles, 1st step

pile floor
level

Figure 2. The placement of pile cage

2.3. The area of the column connected to the pile:

After the first stage of the pile Concreting, the pre-fabricated columns are placed inside the piles. The
buried depth of these columns inside the pile should be calculated so that the column can transfer the total
axial power (shear force) and its bending anchor to the pile. When placing these columns, care must be taken
to ensure that the columns are completely vertical to avoid deflection (for instance: using a crane, using a
pre-fabricated frame, etc.). After the second step of the pile Concreting (in a way that the columns can
transfer their force properly), the circle around the column inside the well should be filled with appropriate
materials (non-condensable) to involve the entire baseplate with the soil. Then, the baseplates are fixed in a
pile using bolts.(Figure 3)

Bolts and nuts

plate

bolt
Bundled bar

Figure 3. Placement of the baseplate on the pile

2.4. Placement of columns:

After preparing the baseplates on the piles, the columns are placed on the plates. At this stage, we ensure
the perpendicular position of the columns by reading the different points of the column from the mapping
stations located on the project site. In high-rise buildings, according to the number of floors, the construction
of each column is done in several steps.

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 2.5. Horizontal beams between the columns in the vicinity of the soil and the construction of the
retaining wall1:
After placing the columns and ensuring the precise connection of the column to the pile, the first stage of
excavation begins.
This step can be done in two ways:
2.5.1. Indented Method: In this method, the excavation is carried out up to the basement level at a
distance of about 5 meters at each step. Then, the beams between the columns are connected.
Finally, after completing the retaining wall, the next 5-meter excavation begins. (Figure 4)

Concrete wall
connection
with column
① ② ③

column 5m 5m 5m

Figure 4. Indented excavation method

2.5.2. Continuous Method: In this method, excavation in all panels is carried out along a 1 to 1.5-
meter height - depending on the type and characteristics of the soil (Figure 5). The horizontal
beams are installed between the columns. In the end, the retaining wall is constructed in this
section, and it continues to the foundation level (Figure 6).

Concrete wall
connection with
column
1-1.5m

column

Figure 5. Continuous excavation method

The main task of the flanges, as well as the shear connectors on them, is the transfer of tensions from the
soil to the side columns. Also, their vertical spacing is calculated according to force, subsidence level, and
soil type. As stated above, this method is more likely to be used in excavations at high depths, which
sometimes causes the foundation level to be lower than the water table. To deal with moisture in these
conditions, after connecting the beams adjacent to the soil and before the reinforcement grid, first, the trench

1 The retaining wall includes the implementation of reinforcement and formwork

4
 surface is paved with shotcrete for the insulation. After that, the retaining wall is constructed. This
waterproofing directs groundwater to the lowest level of the building.
To continue the excavation and consolidation steps, the reinforcement grid and the insulating layer must
be placed pending at the lowest level in order to be connected to the lower layer.

Concrete
wall beam

column

Figure 6. The beam and retaining wall

2.6. Main Beams:
During the excavation and consolidation of the trench walls with concrete retaining wall and horizontal
beams, when the excavation depth reaches 3 meters, the main beams of the structure are placed in the first
upper level. These beams act as strut beams and prevent the increase of lateral displacements of the structure
due to the side pressure of the soil. If the building is retrofitted against lateral loads using a simple space
frame, mixed systems with lateral bracing and etc., such elements should also be implemented
simultaneously with placing the beams at the first upper level of the ceiling. The bracing system is not
necessary for the bending frame system, and the rigid connection between beams and columns alone can bear
the lateral weight of the soil.(Figure 7)

column

Concrete wall

3m
Main beam

Secondary
beam

Figure 7. Connecting the main beams of the structure

5
3. VALIASR GOL TOP-DOWN CONSTRUCTION PROJECT
In the previous section, we introduced the general meaning and implications of the Top Down Method.
As we know, there is a lot of differences from the idea to the implementation of any theory or new method.
These differences in some cases lead to new activities, varying up to the limitations and problems of each
project. In this section, after reviewing each stage of Valiasr Gol Top-Down project, we will investigate its
problems and how the engineers of the project have responded to these problems.
3.1. Introduction:
The Gol project started in June 2014 with a mechanical excavation at the intersection of Valiasr St. and
Mirdamad St. on a site with a total area of 2,500 square meters. (Figure8) With regard to the overall level of
the project, which consists of 9 underground floors (basement level -30/70 m) and 14 floors in height [3]. The
walls during excavation should be retrofitted against the lateral forces of the soil.

Valiasr st

Mirdamad blv

Atar st
DamanAfshar
st

Figure 8. Site Location and Access [4]

In the eastern, western and southern parts of the project excavation, nailing, rebar net, reinforcing bar,
shotcrete, construction of soldier structures, etc. were used for this purpose. On the northern side of the site,
especially in axes 1 and 2, due to lack of permissions from the neighboring landlord, it was not possible to
use the nailing method; therefore, taking into account geotechnical considerations, the excavation was
performed by maintaining the required distance and using well-calculated berms. The top-down method was
used to run the simultaneous excavation and construction. (Figure 9)

Figure 9. Plan for Columns and Lateral Bracing [3]

6
 3.2. Project Review:
3.2.1. Starting excavation and running berms on the northern side:
After starting the excavation, the construction of the soldier structure in the northern side began. In the
second stage of running the berm (the second step), the northeast section of the site subsided due to the loose
soil. In order to consolidate and ensure the proper role of the berm, the truss soldier structure was
implemented in front of it. The truss structure was extended to level 3 in the north and northwest part of the
project to reduce project risk and improve safety. (Picture 1 and 2)

Picture 2. The extension of the truss soldier structure Picture 1. The extension of the truss soldier structure

3.2.2. Drilling the wells of the northern main columns - axis 1 and 2:
Top-Down Process of Valiasr Gol Project was started by drilling the wells of the columns at axes 1 and 2 in
the northern part of the site. During the well drilling, because of going down the groundwater and water
penetration into the wells, the water was pumped out. (Picture 3 and 4)

Picture 4. Pumping out the water during well Picture 3. Drilling well
drilling

The high level of groundwater was one of the problems that occurred during the excavation of the columns.
In the initial stages of the project and before the foundation, a proper drainage channel was created for the
safe transfer of water under the building foundation. A multi-layered insulator with the following
characteristics was implemented on the drainage channel:
1) Geo-membrane layer, 1 mm in thickness
2) GCL (Geo-synthetic Clay Liner) layer
3) Geo-textile layer, 300 mm in thickness
4) Geometric layer, 15mm in thickness
5) Geo-textile layer, 500
The process of drilling the wells under the main columns was as follows: the water was removed from the
wells of the columns by pumping, and the excavation operation continued. At the final stage, once the well
reached the bottom of the foundation level (implementation of drainage under the foundation), the drilled
well was connected to the drainage channel in order to allow the water continue its natural pathway under the
foundation. (Picture 5 and 6)

7
 Picture 6. Floor drainage Picture 5. Moisture Insulation of the floor

3.2.3. Drilling the wells under the northern main columns, axis 1 and 2:
The columns were placed for the proper placement of the piles in the required level of concrete, except for
the well bottom level. After that, the prefabricated pile cages were performed at the site, and then the piles
were placed in the wells by crane. (Picture 7 and 8)(Figure 10)

Picture 8. Building the pile cage in site Picture 7. Placing the pile cages by crane

plate

Grout

Bundled bar
(24#28)
Bolts

Figure 10. Details of the baseplate connection [5]

3.2.4. Placing columns on the piles:

For perpendicular placement of the columns, two readings by the camera were used. After ensuring correct
placement of the column, the bolt head screw is secured by a special device. (Picture 9 and 10)

8
 Picture 10. Placement of axis 2 columns Picture 9. Placement of axis 2 columns

3.2.5. Implementation of arches and arc network of perimeter walls:

It was possible to take the berm step by step with placement and installation of columns in the northern part
of the project in axes 1 and 2. The berm excavation operation was carried out manually due to the insufficient
space for machinery, and shotcrete was applied for the leveling of the concrete wall. At this stage, the main
and lateral beams were placed between the installed columns. In other words, the grid of columns and beams
was completed. (Picture 11 and 12) Once the grid was completed at the berm level, the insulation of the
northern wall was performed similarly to the layers described in Section 1. (Picture 13 and 14) In the end, the
perimeter wall reinforcement network - the northern retaining wall - was constructed on the installed lateral
beam in order to provide the precondition for the highest wall Concreting. (Picture 15 and 16)

Picture 12. Connection of the columns to the Picture 11. Connection of the columns to the
main structure - Implementing the main beams main structure - Implementing the main
beams

Picture 14. Shotcrete for leveling the wall Picture 13. Insulation of the wall

9
 Picture 16. North-2 Wall Reinforcement Picture 15. North-1 Wall Reinforcement

In this project, after starting manual berm excavation, the subsidence of the neighboring soil was more than
expected, and the subsided area prevented the continuation of work. For this reason, the relevant area was
covered by a layer of expanded metal lath and sheets of wood fiber and chipboard in order to protect the
neighboring privacy. Then, the gap between the chipboard and the soil area - the soil area – subsided soil -
was filled with soil cement. The insulation was done on the chipboard. With the provision of excavation
conditions, first stage manual excavation was started. The red area in Fig. 11 represents the first level of
manual berm excavation. After the excavation, an area of the neighboring ground subsided, which was higher
than predicted area. The red area in Fig. 12 shows the volume of the soil subsided from the neighboring
ground. To strengthen the subsided area and also to facilitate the implementation of the north wall insulation,
the chipboard Concreting was executed, and the subsided area was filled with soil cement (Figure 13).

Figure 11: The first berm excavation area

10
 Neighbor

Border

Figure 12: The subsided area

Figure 13: Implementation of chipboard and soil cement mixture

The following pictures (pictures 17,18,19 and 20) show the steps of Concreting and soil cement mixture in
Valiasr Gol Project.

Picture 18: Insulation on chipboard

Picture 17: Soil Cement Mixing

11
 Picture 20: Expanded Metal Lath and Picture 19: Expanded Metal Lath and
Chipboard Chipboard

3.2.6. Installation of molds and Concreting of walls:

After completing the arrangement of the wall reinforcement grid, the Concreting floor was covered with
expanded metal lath, and the molding of the north wall was done unilaterally, and then Concreting was done.
The wall is constructed in the space between the chipboards and the molds, and its lower surface is located on
the lateral beams so that the weight of the wall is temporarily placed on this beam until it is completed and
reached the foundation level. (Picture 21 and 22)

Picture 22: Placement of the wall on the Picture 21: Molding of North-2 Wall
lateral beam

After the next Concreting step, an empty space remains between the two concreting steps, which is finally
filled with grout. (Picture 23 and 24)

Picture 24: Place of the beam between the two upper Picture 23: Filling the empty space with grout
and lower walls

12
 10. CONCLUSIONS

The construction industry has long been struggling with many unforeseen problems. Problems like climate,
environmental, soil conditions, and other areas are on the way to the industrial engineers and architects.
Therefore, continuous efforts have been made to offer new and effective ways of solving them by the
relevant experts. One of these new methods is the Top-Down construction method. In this method, the
construction starts from the available levels of the ground and continues to lower levels with the application
of different methods and attention to the safety of the construction.
The features and advantages of the Top-Down method can be summarized as follows:
1- Ability to implement the structure simultaneously both from up and down
2- Saving the construction time of the main and soldier structures
3- Construction of soldier structures at a lower cost before placing the columns; or not implementing
the soldier structure under some circumstances
4- Using the main structural members of the building to control soil tension after placing the column
5- Implementation of permanent maintenance system and removal of temporary stabilization costs
(construction of retaining wall).
The disadvantages of this approach include:
1- Increasing excavation costs due to manual implementation of some steps
2- The need for precise control and the use of specialist personnel
3- The need to review the soldier structure design (lateral beams) and various analyzes during the
implementation.
4- It may need some soil improvement techniques and good dewatering system.
5- Equipment for these works may not be readily available.
6- Handling of excavated soil material require planning, keeping in mind marine clay at upper level
and silty sand at lower level
First, a specific state of this method was explained and examined. Then, by presenting an illustrative and
comprehensive example of how this approach was applied to a case study in Tehran, an attempt was made to
transfer this concept to the readers directly and completely. It should be noted that the defined method was
successfully implemented in the project and no specific problem was reported afterward.

11. ACKNOWLEDGMENT

Thanks to Roof-truss and Nazm-poya-bana companies that helped us to perform this research.

12. REFERENCES

[1] G. Dizdar, G. Čeliković. 2011. Deep excavation construction by the top-down method in Zagreb.
Proceedings of the 21st European Young Geotechnical Engineers Conference in Rotterdam, 2011
[2] Andrew J. Whittle. 1992. Analysis of Deep Excavation in Boston. Journal of Geotechnical Engineering
Volume119 issue 1
[3] Valiasr Gol project documentation. Contractor for metal framework and Top Down of Roof-Truss
Company, Nazm-Poya-Bana Co. 2015
[4] Google Maps. (2014). Retrieved from
https://www.google.com/maps/place/Paytakht+Computer+Center/@35.7627882,51.4109852,15z/data=!4m5
!3m4!1s0x0:0x18c14e6e556e4b11!8m2!3d35.7627882!4d51.4109852
[5] Designing according to 3-8133 National Standard / Steel for concrete reinforcement - Part 3: Steel
Features / Institute of Standards and Industrial Research of Iran

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