Proceedings of the World Tunnel Congress 2014 – Tunnels for a better Life. Foz do Iguaçu, Brazil.

Management of unexpected swelling clay on Cairo Metro line 3

Phase 2
B.Lecomte, S.Giuliani-Leonardi,
VINCI Construction Grands Projets, Rueil-Malmaison, France.
R.Eymery
VINCI Construction Grands Projets Cairo, Egypt
J.F. Serratrice
CETE Méditerannée, Aix-En-Provence, France

ABSTRACT: During the construction of Cairo Metro Line 3 Phase 2, ground investigations
highlighted the presence of unexpected swelling clay at the tunnel elevation around Cairo Fair
station. In order to control this event, investigations were ordered so as to understand why an initially
stable clay layer could swell in such large proportions in case of excavation below the water table.
Considering the very high potential swelling behavior and the associated time dependent effect on
the next 100 years, a specific design was then developed and implemented on site. On the Cut &
Cover station, a fuse layer (up to 60 cm thick) made with a specific polystyrene material was
installed below the raft level. On the bored tunnel section, several sections were investigated and
iterative calculations were then performed so as to estimate the clay strain amount in the influenced
swelling clay layer. The conclusion was that the swelling effect had no impact on the tunnel lining
design.
1 INTRODUCTION behavior of the considered clay layer. The
design of the fuse layer below raft level of the
When the Egyptian-French Joint Venture, with station will then be described in detail. Finally,
VINCI Construction Grands Projets as leader, tunnel behavior in the presence of swelling clay
was awarded the Phase 2 of the Cairo Metro will be presented.
Line 3 in June 2009, the knowledge of the
anticipated ground conditions was not
sufficiently detailed. 2 CAIRO METRO LINE PHASE 2
Ground investigations performed for the
purpose of the bid around Cairo Fair station
highlighted clay layers just below the raft, but 2.1 Project location
swelling behavior was not suspected. Ground In contrast to most completed tunnels projects in
investigations for the detailed design later Cairo, Cairo Metro Line 3 Phase 2 is not located
showed that this clay layer had a very high in the lower Nile valley, but on East Cairo's hills
swelling behavior. (see figure 1) where no major tunneling projects
As a consequence, dedicated soil have ever been completed prior, to the
investigations were decided and executed. A execution of Phase 2.
specific study followed with the aim of
managing the problems caused by this swelling Phase 2 project consists in:
behavior of the soil below the raft of Cairo Fair - Building five 150 meters long Cut & Cover
station. On the TBM tunnel section, detailed stations with diaphragm wall technology,
investigations and calculations showed that the - Boring an 8.35 meters inner diameter tunnel
swelling behavior was not affecting the segment with one slurry TBM and one EPB TBM
reinforcement design. over a length of about 7.1 km,
After a brief description of the Cairo Metro - Excavating seven circular Evacuation Shafts
line 3 Phase 2, this paper details the swelling located between stations.

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 Proceedings of the World Tunnel Congress 2014 – Tunnels for a better Life. Foz do Iguaçu, Brazil.
Figure 1 : Major tunnels project in Cairo city
2.2 Ground data during the bid period
For the purpose of the bid, some ground
investigations had been performed along this 8
km long project:
- 30 boreholes with SPT tests and piezometers,
- Laboratory tests with sieve analysis,
identification tests and direct shear tests or
UCS tests for cohesive ground.
Based on this preliminary investigation, it
was anticipated that a coarse sand layer with
some interbedded clay layers would be
encountered on most of the alignment. From the
interstation between Cairo Fair and Stadium
stations and till Haroun station, the water table
was expected to be below the project elevation.
2.3 Ground survey for detailed design
Before the start of the detailed design, some
additional investigations were performed along
the project alignment. They consisted of:
- 32 boreholes with SPT tests and piezometers,
- 12 pressuremeters tests,
- Pumping tests on Cairo fair station,
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- MASW geophysical survey on Cairo Fair
station,
- Laboratory tests
2.4 Cairo Fair station
Cairo Fair station was critical for Phase 2
project because both TBMs had to begin their
excavation work from this station in both
directions. Figure 2 shows the assumed
longitudinal profile around this station taking
into account the additional ground investigation.
The construction of this station was more
challenging than anticipated because of:
- The presence of an unusual limestone layer at
the diaphragm-wall embedment elevation,
inducing some difficulties for the diaphragm-
wall excavation,
- Dewatering needs that were more important
than anticipated in the station,
- The presence of a swelling clay layer at the
base of the Cut & Cover station.
In the next sections, we will focus on this
swelling clay behavior and how this behavior
was controlled on the cut & cover station and
TBM tunnel.
 Proceedings of the World Tunnel Congress 2014 – Tunnels for a better Life. Foz do Iguaçu, Brazil.
Figure 2 : longitudinal geological profile around Cairo Fair station
3 SWELLING CLAY BEHAVIOR
3.1 Clay layer main characteristics
According to the investigations performed on
site and in Egyptian laboratory during the
detailed design stage, this lower clay layer:
- Is an homogeneous greyish-brown hard clay
layer with SPT value around 30, limit
pressure around 2 MPa and Menard modulus
around 40 MPa,
- Has fine content of approximately 85% and
clay content (particle percentage inferior to
2μm) of around 33%,
- Has liquid limit around 104 and plastic limit
around 54, which means this clay layer is
very plastic, with plasticity index around
Ip≈50,
- Has free swelling index of around 210% as
per ASTM D4546.
Based on these observations, it became clear
that this lower clay layer had a swelling
behavior, which needed to be further
investigated (in contrast with the upper clay,
which did not have swelling characteristics).
3.2 CETE laboratory involvement
Following the identification of this risk, it was
decided that complementary analysis in
collaboration with the French CETE
Méditerranée laboratory should be performed.
This laboratory is well known for its expertise
in swelling ground behavior.
As a consequence, new samplings were
performed with triple core barrel technology so
as to limit clay remolding as much as possible.
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Samples were then sent to France to carry out
the following tests:
- Clay identification with mineralogy analysis,
- Swelling oedometric tests,
- Simplified shrinkage and swelling tests.
3.3 Laboratory tests results
The main identification tests confirmed the
results highlighted by the preliminary tests. In
addition, according to its mineralogical analysis,
this clay is essentially made up of smectite
particles (around 86% of the clay and 77% of
the rock particles), which highlights its potential
swelling behavior. Methylene blue tests also
confirmed this high smectite percentage.
Several oedometric tests were then
performed in parallel, with the introduction of
water within each tested sample at a selected
state of stress. These tests highlighted a very
large swelling behaviour, both in terms of strain
and force (see figures 3 and 4), with important
swelling when water was introduced (except for
tests made under very high stresses).
Figure 3 : clay sample at the end of the test (initial
height of the sample was the ring height)
Finally, additional tests based on K0 high
pressure oedometric test and shrinkage-swelling
tests confirmed the swelling sensitivity of this
lower clay layer.
 Proceedings of the World Tunnel Congress 2014 – Tunnels for a better Life. Foz do Iguaçu, Brazil.
Figure 4: oedometric tests results in case of water condition change
3.4 Clay swelling modeling principle
Based on usual theoretical approaches and
understanding of the physical phenomenon, and
upon analyzing time and stress relations from
the laboratory tests, the clay swelling in case of
water presence can be modeled as follows:
 2  T 1 / 3 lnT   1  lnT 2   
 t ,    b       1 
 1  2  T  10  
With:
t 
- T  a  , time/stress factor
t u  ag
- σ, the applied effective stress on the sample
(in kPa)
- σag, the swelling pressure (in kPa)
- t, the time (in hours)
- tu, the unit time (1 hour)
- a and b, 2 local factors depending on the
investigated clay.
Even if the considered formula might seem
quite complicated, it is easily explainable. As
defined in the ASTM D4546, swelling related to
changes in the water content can be divided into
2 phases:
- Phase 1: primary swell, which more or less
corresponds to a “short term swelling”.
Considering settlement issue on soft clay
layers, this phase is in fact similar to a
consolidation phase. In the proposed formula,
the phase 1 primary swell corresponds to the
factor:
1/ 3
 2 T 
 
1 2 T 
 ag  It is interesting to note that the proposed
 factor is in line with what is usually admitted
 
when we encounter settlement issue. Note
also that when T is large (i.e. time is large),
this factor tends to 1, which means that it is
the end of this primary phase.
- Phase 2: secondary swell, which corresponds
to a long term swelling. Considering
settlement issues on soft clay layers, this
phase is in fact similar to a creep
phenomenon. In the proposed formula,
secondary swell corresponds to the factor:
lnT   1  lnT   2

10
Note that when T is large (i.e, time is
large), this factor tends to ln (T), which is
homogenous with what is usually modeled
when we face creep phenomenon on soft
clay.
Consequently, the 2 factors which are
proposed for strain estimation are homogenous
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 Proceedings of the World Tunnel Congress 2014 – Tunnels for a better Life. Foz do Iguaçu, Brazil.

with what is usually used on settlement design.
Note also that load effect is taken into account
in the formula so as to follow as much as
possible the reality measured in the tests.
Finally, it is worth highlighting that the
proposed formula deals with thin samples,
where the delay effect related to the water
diffusion is quite limited.
3.5 Swelling rate speed estimation
As it is usually done in cases of settlement
design, it is then necessary to estimate a
swelling rate speed. As defined in ASTM 4546,
this means that a boundary (called t100) between
primary swell and secondary swell needs to be
estimated based on the loading stages of the
performed tests (see figure 5).
4 SWELLING BEHAVIOR BELOW THE
STATION
4.1 Swelling generation
As previously stated, there is a swelling clay
layer below the raft base that is below the water
table on Cairo Fair station. Constructing the
station requires excavation down to this clay
layer, creating a sudden decrease of the total
vertical stress of the clay.
Contrary to settlement issues on the soft clay
layer, the excavation will induce (via this
unloading) a sudden decrease of the pore water
pressure. At the same time, the vertical effective
stress will slowly reduce so as to reach an
equilibrium state. Figure 6 below presents the
typical evolution of stress of this clay layer with
respect to time:

800 kPa

400 kPa

200 kPa

100 kPa
t50

50 kPa

t100

Figure 5 : displacement vs duration for different loads

As usually done with consolidation tests,

swelling speed Cv can be estimated through the
definition of t50 duration (duration
corresponding to 50% of the primary swelling)
as per figure 5.
Then swelling speed can be estimated
through the following formula:
0.197  H 2
Cv 
4  t 50

3.6 Assumed swelling characteristics

On this specific Cairo Metro project, oedometer
tests results allowed the following design values
definition:
- σag=900 kPa Figure 6: swelling mechanism below a station raft
- a=0.05, b=0.035
- Swelling rate speed: Cv=7.10-10 m²/s, As we can see, because of the required
considering t100 equal to 480 hours based on excavation, some negative pore pressure will
tested samples. appear just after the excavation. This negative
pore pressure will induce some suction inside
this clay layer. Consequently, water content will
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 Proceedings of the World Tunnel Congress 2014 – Tunnels for a better Life. Foz do Iguaçu, Brazil.

change in this clay layer after the excavation. It durability and behavior have already been
will then induce some swelling into this clay checked and tested,
layer, which needs to be controlled and - It is a controlled material,
managed over the years. - It is a material which perfectly suits
requirements because it is an elastic quasi
perfect plastic material with the typical
4.2 Mitigation proposal strategy stress-strain curve presented in figure 7:
In order to mitigate the anticipated swelling
effects on the raft design for the next 100 years
(station lifetime), several strategies were
successively considered:
- Designing a raft able to support the full
swelling pressure. This would mean that the
raft should be able to support a 900 kPa load,
which is too large. Because of the
consequences on the raft design, this solution
was disregarded.
- Allow a free swelling of the clay without
any stresses below the raft. This means that
the raft should be designed as a slab resting Figure 7: typical polystyrene behavior
on the diaphragm walls. However, because
the swelling increases when the vertical For typical polystyrene material, εmax is
effective stress decreases, calculations have usually more than 50% while σel and σmax
shown that this solution would have required usually depend on polystyrene density. After
too much void thickness (that is to say over- having performed a series of laboratory tests on
excavation) between the base of the raft and polystyrene samples (see figure 8), a
the top of the clay. Consequently, such a polystyrene with 24-25 kg/m3 density was
solution was also disregarded. selected as most suitable.
- Allowing a maximum and controlled
effective stress of the clay layer, so as to
reduce the swelling effect as much as
possible while keeping the upward stress
below the raft at reasonable levels. Finally,
this solution was developed.

4.3 A fuse polystyrene thickness

In order to control both the clay swelling and
the associated stress, the best solution consisted
in placing a fuse layer below the raft. This layer
needed to be designed so as to:
- Transfer the stress between clay and raft as
long as the stresses remained low,
- Crush when the swelling pressure is too
important while continuing to transfer a
reasonable stress value.
After a review of potential materials which
could be used, it was decided to use polystyrene
material for many reasons:
- In civil engineering, polystyrene has been
used for decades for building very light
embankments in poor soil conditions. It is
consequently a well-known material, whose
Figure 8: polystyrene compressibility
4.4 Swelling generation development with time
Considering the swelling mechanism and the
pore pressure distribution inside a clay layer, it
is easily understandable that the influenced
thickness of swelled clay will increase with
time, as observed for consolidation theory in
case of settlement with soft clay layers. For a
considered time duration t and a total clay
height H, the associated influenced thickness
percentage can be estimated based on the typical
consolidation percentage formula:
1 C t
U%  1/ 6
TV  V 2
  H
1  1 
 2 T 3 
 V 

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 Proceedings of the World Tunnel Congress 2014 – Tunnels for a better Life. Foz do Iguaçu, Brazil.

When using this consolidation formula, it is Finally, the following swelling curve
then possible to estimate the thickness of the presented in figure 10 has been obtained, with
ground influenced by swelling with respect to the main swelling results:
time, and consequently the swelling value for a - 5 cm after 5 years
considered time t and a total clay height equal to - 8 cm after 10 years
H: - 14 cm after 10 years
t - 28 cm after 100 years
swelling value   delta h j    t  j ,  
j 0
4.6 Polystyrene fuse thickness estimation
4.5 Swelling estimation below the raft Based on sensitivity analysis made on clay
thickness, swelling speed and effective stress, it
Calculations were made considering a 6 meter was finally decided to install a 60 cm thick
thick clay layer with an average effective stress polystyrene layer below the station raft. Figure
within the clay below the raft equal to 50 kPa as 9 shows the placing of the polystyrene layer
given by the polystyrene layer. This value was before the pouring of the raft lean concrete.
resulted of mechanical characteristics of the
selected 24-25 kg/m3 polystyrene:
- Elastic stress σel of the polystyrene is
superior to the raft concrete dead load and
the on-site water pressure plus some safety
factor. Indeed, we do not want any
polystyrene crush because of concrete load or
water pressure.
- εmax>50% is considered for fuse purpose,
- A maximum allowable stress equal 200 kPa,
based on engineering judgment.

Figure 9: placing of the polystyrene layer

0.30

0.25

0.20
Swelling value (meters)

0.15

0.10

0.05

0.00
0 10 20 30 40 50 60 70 80 90 100
Time (years)

Figure 10: swelling generation with time below the raft

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 Proceedings of the World Tunnel Congress 2014 – Tunnels for a better Life. Foz do Iguaçu, Brazil.

5 SWELLING BEHAVIOR AROUND THE

TUNNELS

5.1 Potential origin of swelling behavior

In the vicinity of Cairo fair station, tunneling
excavation with TBM was to be done within the
lower clay layer, as shown on figure 2. Also,
based on the conclusion drawn in section 4, it
was considered mandatory to check and analyze
the tunnel behavior in all configurations of the
position of the clay layer relative to the tunnel.

As stated by Serratrice & Soyez in 1996,
swelling phenomena in clay material is usually
initiated by water pressure changes during or
after the works:
- It can be generated by negative pore pressure
generation during the works in relation with
deep excavation. Such should occur around a
tunnel if the total stress change is in practice
superior to the initial water pressure (see
figure 6).
- It can be generated by water pressure
changes in line with hydraulic boundary
conditions related to the associated works.
5.2 Critical swelling zone around a tunnel
In a first stage, a sensitivity analysis was
performed in order to estimate the location of
the most critical zone regarding total stress
change for a clay layer. A FEM analysis was
performed, considering a typical tunnel section
where clay layer thickness and location around
the tunnel is changed depending on the
investigated case (see figure 11).
Figure 11: FEM analysis so to define sensitive
swelling zone
Obviously, it was possible to show that the
most sensitive zone to total stress change
corresponds to a clay layer located in the lower
part of the tunnel. Indeed, whatever the
considered thickness in the lower part of the
tunnel, models show that mean total stress is
reduced by more than 70 kPa on the first 2.6
meters below the bottom of the tunnel. Such a
70 kPa in fact falls within a typical range of
water head at the tunnel axis in the vicinity of
Cairo Fair station.
A detailed analysis of the mean total stress
change results then allowed defining the area
prone to potential swelling behavior, as shown
in figure 12.

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 Proceedings of the World Tunnel Congress 2014 – Tunnels for a better Life. Foz do Iguaçu, Brazil.

several runs of calculations, it was in the end

possible to estimate an average swelling strain
within the area.
As per FEM calculations, it was possible to
estimate the swelling of the clay within the area
prone to swelling to around 3%.

5.4 Swelling effect on the segment

Then, it was possible to estimate this swelling
on the segment design. Figure 13 shows as an
example the anticipated total displacement
shape after a 100 years duration, with up to 20-
30 mm of upward movement related to swelling
effect depending on the considered sections.

Figure 12: definition of the area prone to swelling

potential behavior

Note that the performed calculations are

quite conservative because such an approach
does not consider the delay of swelling
generation within the area prone to potential
swelling, in contrast to the strategy defined for
the swelling below the Cairo Fair raft (see
section 4.4).
Figure 13: total displacement shape
5.3 Swelling estimation around the tunnel
It was finally concluded 20-30 mm
Unlike the swelling estimation below Cairo Fair displacement range during the next 100 years
station, the interdependent strain-stress swelling was acceptable, keeping in mind relative
development had to be studied: displacements would be rather limited because
- As per formula defined in section 3.4, strains the clay layer was quite continuous.
and stresses are highly dependent and
interacted in case of swelling,
- Also, the effect of the 40 cm thick concrete
segment and its associated relative stiffness
had to be taken into account.

Because the calculations are quite

complicated, an iterative approach was
considered assuming first a volume strain Figure 14: axial forces and bending moment shape
definition in the area prone to swelling. This
Concerning forces issues as shown on figure
volume strain change was then the input for the
14 with axial forces and bending moments, it
considered area and FEM calculation was then
could be demonstrated that the tunnel bending
conducted. The average mean effective stress in
moment resisting capacity was not exceeded
the area prone to swelling was then estimated.
while some limited additional normal forces
Finally, back calculation defining the resulting
could be observed. Finally, the segment design
swelling strain was then performed with the
was checked without any additional
analytical formula defined in section 3.4. After
reinforcement.
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 Proceedings of the World Tunnel Congress 2014 – Tunnels for a better Life. Foz do Iguaçu, Brazil.

6 CONCLUSION REFERENCES

On Cairo Metro Line 3 Phase 2, although a
swelling clay layer as shown on figure 15 was
not expected along the project alignment;
detailed investigations highlighted its presence,
with potential risks for the structures to be
constructed. Dedicated tests were then
implemented, which showed that either the
swelling pressure could be up to 900 kPa or free
swelling could be up to 200%.
ASTM D 4546-03: Standard Test Methods for One-
Dimensional Swell or Settlement Potential of
Cohesive Soils
Serratrice, J.F and Soyez, B. 1996. Les essais de
gonflement in Bulletin des laboratoires des Ponts
&Chaussées

Figure 15: typical swelling clay observed during Cairo

Fair excavation

For a deep excavation like a Cut & Cover

station, excavation would generate negative
pore pressure and then initiate swelling
generation of such a clayey ground. In order to
master this problem over the 100 years station
lifetime, a specific design was implemented. It
showed that a fuse layer made with a 60 cm
thick polystyrene of 24-25 kg/m3 density should
be placed below the raft. Such a fuse layer will
avoid any disorder in relation with the
anticipated 30 cm swell below the raft.
On the tunnel section, strain-stress
interaction calculations coupled with FEM
analysis segment design showed that although
some 3% swelling may be generated below the
tunnel raft, the segments' design was safe
enough and there was no need to additionally
reinforce them. Some limited upward
movements must however be considered over
the next 100 years.

ACKNOWLEDGEMENTS

The authors would like to thank the National

Authority for Tunnel and its representatives for
their supports and confidence concerning this
specific design issue.
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