GROUND IMPROVEMENT WORKS IN DFCCIL

PROJECT - A CASE STUDY Ramakrishna Raju N

VP – Head Engineering

1
GROUND IMPROVEMENT WORKS IN DFCCIL PROJECT -
A CASE STUDY

PROJECT INFORMATION

2
 PROJECT DETAILS

Project :
DFCC Contract Package- CTP-11

Client:
Dedicated Freight Corridor Corporation of India Ltd.

Contractor:
EFRC (Express Freight Railway Consortium) - (TPL,
IRCON, MITSUI & Co. JV)
Scope:
Design and Execution of JNPT–VAITARANA Section of
WDFC- Total length 103km

3
 ALIGNMENT PLAN
Scope of work Tunnel
Vasai Vaitarana
EW in filling 88 L cum
EW in cutting 42 L cum
Subgrade 20 L cum
Blanket 10 L cum

Project End: 101.625

Ch. 95+000
Project Start: -1.276

Tunnel 2 Nos. Ch. 85+000

(Longest 1.73km @ Kalamboli) Ch. 90+000
Viaduct 9 Nos.
Viaduct No. 152 & 153
RFO 2 Nos.
Major Bridge 25 Nos. Ch. 80+000
ROB/MJRUB 19 Nos. Juichandra
Minor Structure 252 Nos.
Supply of Ballast 6.27 L cum Ch. 75+000 Viaduct No. 172
Sleepers 3.62 L Nos. Viaduct No. 163C & 166
Rail 25715 MT
Ch. 0+000
Mechanized Track laying 238 TKM Ch. 70+000
Station Yard 3 Nos.
Ch. 5+000 Station Buildings 3 Nos.
Ch. 65+000

Ch. 10+000 Kundevahal Viaduct Ch. 60+000Kharbao Viaduct

Kundevahal Detour = 1.6 Km Kopar Viaduct
Ch. 15+000 Dativali Detour = 3.2 Km
Ch. 55+000

Ch. 40+000 Ch. 45+000 Ch. 50+000

Ch. 20+000 Kalamboli Viaduct Ch. 35+000
Nilje
PANVEL Ch. 25+000 Ch. 30+000
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 ALIGNMENT PLAN

VIATARNA
END
DFCC (South)
JNPT
END

Kharbao Vasai Detour

PMC-2R
(ZMT) Nilje Kharbao RFO

NTC & Sleeper

Yard
Kundevahal
Detour Datival Detour
Kalamboli RFO

Legends:
Existing Track -
Proposed DFCC Track -

5
ALIGNMENT PLAN

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 ALIGNMENT PLAN

Kundevahal Detour
JNPT Jn Stn Ch. 13.30 to Ch. 14.90 Kundevahal Viaduct
Ch. 0+577 Ch. 15+148 Tunnel -1 Tunnel -2
Kalamboli Viaduct Kharbao Viaduct
Nilije Crossing Ch 92.420 Ch 94.3700
DFCC Track Ch. 28+990 Ch. 67+000
Kopar Viaduct
Ch. 51+000
IR Track

JNPT
Ch. -1+276
Datiwali Detour Vasai Detour Kopar Viaduct
ROB - Gawan PhataCh. 11+070.97 Prop Nilje RS Major Bridge 4 Kharbao Jn Stn
ROB - Vahale Dumale Ch. 12+143 Ch. 45.70 to Ch. 48.90 Ch. 82.00 to Ch. 98.625
Ch. 37+928 Nos. TDC : Jul-21 Ch. 72+578 VAITARANA

100.000

102.500
15.000

17.500

20.000

22.500

25.000

32.500

35.000

37.500

40.000

42.500

45.000
27.500

30.000
10.000

12.500

47.500

65.000

67.500

82.500

85.000
50.000

52.500

55.000

57.500

60.000

62.500

70.000

72.500

75.000

77.500

80.000

87.500

90.000

92.500

95.000

97.500
2.500
0.000

5.000

7.500

Chainage

SECTION -1 : KM.-(1+276) to 44+00 SECTION -3 : KM. 82+00 to

SECTION -2 : KM. 44+00 to 82+000

7 7
 NTC MOVEMENT
End of
JNPT Yard Nilje Yard Nilje Yard package

Ch. 50

Ch. 60
Ch. 30

Ch. 80
Ch. 20

Ch. 70
Ch. 10
Ch. -1.276 Ch. 37.5 Ch. 69.2 Ch. 101.6

Kundevahal Kalamboli Kopar Kharbao Tunnel

NTC Depot
Ch. 42.7
Depot Stations
104.7 TKm 133.7 TKm
NTC rate- 1.0 TKM/Day NTC Start

10-Dec’21 15-Mar’21
09-Jan’22 08-Jun’22

104.7 TKm 133.7 TKm

JNPT Ch. 42 to Ch. -1.276 Ch. 42 to Ch. 101.625 Vaitarna
Nilje

May-20

May-21

May-22
Mar-20

Mar-21

Mar-22
Nov-19

Nov-20

Nov-21

Nov-22
Aug-19

Aug-20

Aug-21

Aug-22
Sep-19

Dec-19

Sep-20

Dec-20

Sep-21

Dec-21

Sep-22

Dec-22
Feb-20

Feb-21

Feb-22
Jun-19

Oct-19

Apr-20

Jun-20

Oct-20

Apr-21

Jun-21

Oct-21

Apr-22

Jun-22

Oct-22
Jan-20

Jan-21

Jan-22
Jul-19

Jul-20

Jul-21

Jul-22
Duration
Item Description Unit Scope Start Finish
(Months)

Construction of NTC Yard 8.0 15-Jan-19 30-Aug-19

Sleeper Yard Construction 10.0 15-Nov-18 30-Aug-19

Sleeper Production & RDSO app. Nos. 10,000 2.0 31-Aug-19 15-Oct-19

Sleeper Production Nos. 3,52,180 20.0 16-Oct-19 30-May-21

Supply of Japanese Rails MT 27,000 9000 9000 9000

NTC Machine shifting to CTP-11 site 2.0 15-Dec-20 15-Feb-21

Trial run of NTC at site 0.5 15-Feb-21 02-Mar-21

Laying of track to start for Sec -1 TKm 104.72 6.3 15-Mar-21 10-Dec-21
Laying of track to start for Sec -2 TKm 133.73 5.0 09-Jan-22 08-Jun-22 8
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GROUND IMPROVEMENT WORKS IN DFCCIL PROJECT -
A CASE STUDY

GROUND IMPROVEMENT

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 NEED GROUND IMPROVEMENT

 Existing marshy land with soft marine clay

 DFCC trains with 32.5 T wheel load

 Embankment height varies from 2.5m to 15m

(60 to 220kPa)

 Low Bearing capacity (20 to 30kPa)

 Existing IR parallel to proposed DFCC lines

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 GROUND IMPROVEMENT - METHODS

GI with out Admixtures GI with inclusions

 SOIL REPLACEMENT  STONE COLUMNS

 PRECOMPRESSION/PRELOADING  SAND COMPACTION PILES
 PRELOADING WITH SAND PILES/PVDs  SOIL NAILING
 VACCUM CONSOLIDATION  GEOSYNTHESIS

GI with Grouts/Chemical
Admixtures

 CHEMICAL STABILISATION
 LIME STABILISATION
 DEEP MIXING
 JET GROUTING
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 GROUND IMPROVEMENT METHOD - ADOPTED

SOIL TYPE
MARINE CLAY

REMOVE & REPLACEMENT STONE COLUMNS PRELOADING + PVD

Soft clay layer <2m Soft clay layer >2m Soft clay layer >2m

DFCC track is parallel to IR DFCC track is in detour

Number 80,000 Number 4,20,000

Length 5m to 15m Clay thickness 8m to 15m

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GROUND IMPROVEMENT WORKS IN DFCCIL PROJECT -
A CASE STUDY

GROUND IMPROVEMENT

STONE COLUMNS

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 GROUND IMPROVEMENT – STONE COLUMN

 Sub Soil Profile

 Design Procedure

 Construction Procedure

 Confirmatory Testing

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 SUB SOIL PROFILE

Geotechnical Investigation

Soil Investigation @
Vane shear test @
every 250m
every 250m (to obtain
And the cross drainage
in-situ C values)
structure location

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SUB SOIL PROFILE

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SUB SOIL PROFILE
Table: Field SPT N values with depth Table: Cohesion values for Laboratory
Test results

BH- BH- BH- BH-

BH No. BH-16 BH No. BH-2500
2500 3000 3000 16
Chaina 3801. Chainag
2500 3000 2500 3000 3802
ge 95 e
GL 1.853 3.692 1.317 Depth Cohesion (kPa)
GWT 1.45 1 0 1.5 41 24
Depth SPT N - Values 3.5 12
4
1.5 2 5 3
6.5 16.9 15
3 1 7 0
9.5
4 1 2 0
6 2 2 3 In Situ Vane Shear Test Results
7.5 2 2 2 Chainage BH-2500 BH-3000 BH-16
9 2 100 Depth Cohession in kPa
10.5 100 5 100
12 100 15 100
1.5 55.7
13.5 53 2.5 28.1
15 100 4 28.1 33.8 22.5
16.5 100 7 16.9 28.5

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 DESIGN PROCEDURE
FLOW CHART FOR SOFT GROUND TREATMENT
`

Determination – Height of Embankment and

Loading on Embankment & Loading condition

Study the soil parameters such as SPT N values,

Shear parameters, Consolidation properties

No N<5 Yes Top soft soil No

Ground Improvement not required Adopt Remove & Replacement
Cu < 25kPa thickness >2m

Yes
Summarise the Loading from Embankment (Height and Loading Condition)

Summarise the design soil parameters form the Factual Design report

Perform the Stability analysis and Settlement analysis with-out treatment

Does the deformation of the

ground affects the surrounding
Yes structure such as existing IR
STONE COLUMN
(Parellel/detour), buildings, etc.,
No
PVD’s
Lateral Yes Other treatment
displacement due methods Ex.:
Depp mixing etc., Any limitations for time? Set the PVD – Type, size, spacing, depth Past Experience
to construction
IS 15284 (Part2)
RDSO – GE: G-05
No
Set the Stone column specifications No sufficient Determine the time required for Ureq%
(Diameter, Spacing, Stone Density, Angle of Internal friction, Stress sharing ratio etc) Consolidation with PVD
time available IS 15284 (Part2)
Design Stage loading using Ureq = (Si – Sr)/Si (%)
embankment loading & fix the
stage wise time requirement
Does it meet the Does it meet the Does it meet the to arrive required settlements
required bearing required Slope required No Determine the stage-wise construction & Corresponding Height of rise, time,
Settlement
OR
capacity Stability - FOS settlement and propose the construction plan ie, height of degree of
Requirement? Requirement? Requirement? Not safe then revise stage construction and time consolidation
Design Preloading & fix the
1 time required to arrive
stage height and time
3 2 Meeting the project time schedule
Time available to required settlements
retain preloading

Bearing capacity check stage wise - Calculate the

Yes gain in cohesion for each stage and corresponding Stability Check stage wise – Check the static and
Yes Yes
and check the FOS (1.25) seismic FOS for each stage for gain in cohesion

Summarise the Final Stone column arrangement, spacing, stage construction/preloading
height, maintaining time*1 and list the conclusions
*1 Need adjust embankment height in consideration of residual settlement, three
Summarise the Final PVD arrangement*2, spacing, stage
months after construction
construction height, maintaining time*1 and list the conclusions
*2 Depth of PVD shall be installed up to over consolidation layer

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 DESIGN PROCEDURE

Design procedure reference guidelines obtained from:

 RDSO guidelines GE-G5

 IS: 15284 Part.1 -Design and construction for ground improvement-

Guidelines, Part 1-Stone columns.

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 DESIGN PROCEDURE
Embankment Geometry & Loading: Proposed Soil Type
Layer Description Thickness (m)
(As per GE:0014)
I Blanket Layer SQ3 0.6

II Prepared Subgrade SQ2/SQ3 1.0

III Embankment Fill SQ1/SQ2/SQ3 Varies

Typical Embankment Section

(2.5m Height of Embankment)

Dead load (Ballast, Rail, Sleeper & Embankment fill) (DL) = 42.6kPa

Live load at the base of embankment (LL) = 13.8kPa

Total Pressure at the Base of embankment (DL+LL) = 56.4kPa

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DESIGN PROCEDURE

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 DESIGN PROCEDURE

Load capacity of the treated ground:

 Capacity of the stone column resulting from
the resistance offered by the surrounding
soil against its lateral deformation (bulging)
under axial load

+
 Capacity of the stone column resulting from
increase in resistance offered by the
surrounding soil due to surcharge over it

+
DIAMETER OF STONE COLUMN
 Bearing support provided by the intervening
soil between the columns SPACING OF STONE COLUMN

PATTERN OF STONE COLUMN 22

 DESIGN PROCEDURE

Design summary of Ground Improvement:

 Dia. of Stone Columns : 900 mm

 Depth of Stone Columns : 5m to 15 m
 Grid Pattern : Triangular
 Spacing of stone Columns : 1.8m to 2.40m
 Improved Bearing capacity : 60kPa - 220kPa

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 DESIGN PROCEDURE

Stability Analysis – Untreated Ground Stability Analysis – Treated Ground

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 CONSTRUCTION PROCEDURE

 A special technique introduced for the first

time in India by M/s SARITHAINFRA &
GEOSTRUCTURES – INDIA with collaboration
of McMillan of New Zealand and developed by
Casagrande S.p.A of Italy (Non-Vibro by
Displacement Method )

 The method is bottom feed, so the drill

hole is supported at all times –
surrounded soil densified due to non
vibro by displacement method

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 CONSTRUCTION PROCEDURE

Installation Methodology:
 Locations are marked for installation
 The stone column assembly consists of concentric
cylinders, the outer cylinder having an enlarged lower
section with flights
 Once the machine is at location, the assembly is forced
into the ground using high torque equipment, displacing the
soils primarily in the lateral direction. During installation the
base of the assembly is closed
 Upon reaching target depth a hydraulic cylinder opens the
base of the assembly, exposing the internal stone feeding
mechanism, and engaging a gearbox that rotates the centre
stone feeding mechanism

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 CONSTRUCTION PROCEDURE
Installation Methodology:
Aggregate is loaded into the upper stone bin, and is fed
out of the base of the assembly as the tooling is extracted
from the ground.
The aggregates are compacted both vertically and
horizontally and the degree of compaction monitored by
real time torque output on the rig computer screen.
Once the stone column is completed, it is verified with
the depth and volume to reach the required torque value.

27
CONSTRUCTION PROCEDURE

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 CONSTRUCTION PROCEDURE

Construction Monitoring:
Once the equipment is assembled, it will be shifted to the
exact location of installation.
Initially trial stone columns are installed to know the exact
amount of torque required for installing 900mm dia columns
against volume v/s depth
The density of column is monitored in real time by the on-
screen torque display in the operators cabin. The real time
onscreen display also monitors depth versus torque
The operators & Engineers will know the initial assessment
of the required torque to produce for the required 900 mm
dia stone column by assessing the aggregate volume in the
hopper using the on-board camera and known measuring
points

29
 CONSTRUCTION PROCEDURE
Construction Monitoring:
For a 900 mm diameter stone column, the theoretical
volume of 50mm down aggregate
The excavator bucket volume will be 1.0cu.m and the
telescopic loader bucket volume will be 0.7 cu.m.
Once a bucket full of aggregate is added inside the hopper
with the help of excavator/loader, and by the actual depth
installed, the operator will withdraw the tooling
approximately 900 mm prior to the next bucket of aggregate
being added
The Engineer will note the torque required to feed the
quantity of aggregate in stages over the length of column.
Upon completion of the installation of the first column, the
total number of buckets consumed is noted, and total
volume of aggregate placed for the column is recorded by
Engineer.
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 CONSTRUCTION PROCEDURE
Construction Monitoring:
The torque required to feed the aggregate is also
recorded and the process is repeated
It is expected that by the time 5 test columns are
completed, we will be able to select the required
torque to install columns of the required 900 mm
diameter to meet the design requirements
The ongoing installation is continuously
monitored with the total volume of aggregate
placed per column being recorded and the required
torque used, thus allowing the parameters to be
adjusted as ground conditions changes to ensure
the design requirements are met
Equipment experts will visit regular intervals to
monitor the quality of the stone column
installation.
31
CONSTRUCTION PROCEDURE

32
CONSTRUCTION PROCEDURE

33
 CONFIRMATORY LOAD TESTS
Load tests on Stone Columns

 Load Tests were performed on single & 3-column group

 The Initial test load is 1.50 times the design load.

Acceptance Criteria

As per IS 15284_Part-1 :

 Settlement of 10–12 mm for single column test

 Settlement of 25–30 mm for a three column test

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 CONFIRMATORY LOAD TESTS
Load tests on Stone Columns
 The load was applied by operating a hydraulic jack
against a suitable kentledge
 The load was applied in intervals of 10% of safe load
(design load)
 Settlements were recorded for each load increment
with the help of 4 dial gauges. Settlements were
recorded at every 1, 4, 9, 16, 30 and 60 minutes for
each interval
 Next loading increment was applied if the rate of
settlement was less than 0.05 mm or less in first 15
minutes.
 The design test load was maintained for a period 24
hours
 Each unloading is done in 5 to 6 stages is maintained
till the rebound attained a rate of 1.00 mm in first 15
min
 Load-settlement curve was plotted for each test 35
 CONFIRMATORY LOAD TESTS

Single column load test- 320kN. Group-Three column load test- 960kN.

Test Load - 320 * 1.50 = 480kN Test Load - 960 * 1.50 = 1440 kN.

Total settlement - 6.145 mm Total settlement - 13.062 mm

Net settlement - 4.10 mm Net settlement - 7.12 mm
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 CONFIRMATORY LOAD TESTS

Load Settlement Curve for Single Column Load Test Load Settlement Curve for Three Column Load Test

37
 CONFIRMATORY LOAD TESTS

 The ultimate load works out to be about

480kN for the single column test and the
corresponding settlement is about 6mm and
for three column test, the ultimate load is
about 1440kN and the corresponding
settlement is about 13mm.

 In-group case ultimate load per column is

1440kN which is higher (about 33%) than the
single column case

 The ultimate bearing capacity of improved

ground works out to be 70kN/m2
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 MD DFCCIL Site Visit

 Mr. Anurag Sachan – MD ,DFCCIL  Mr. NRK Raju – Head Engineering , TPL

 Mr. Vivek Gautam – COO , TPL  Mr. Ravi Kumar – MD , SARITHA INFRA
39
 MD DFCCIL Site Visit

Progress of Stone Column Works

40
 Site Photographs

Stone column build

up

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GROUND IMPROVEMENT WORKS IN DFCCIL PROJECT -
A CASE STUDY

GROUND IMPROVEMENT
PRELOADING + PVD

42
 GROUND IMPROVEMENT – PVD + PRELOADING

 PVDs with Preloading implemented in Detour stretches

 PVDs with Preloading are designed based on IS: 15284-Part 2

 Allowable settlement after construction limited to 100mm

 Pre-loading height and Time period decided based on the allowable settlements

43
 GROUND IMPROVEMENT – PVD + PRELOADING
Design summary of Ground Improvement:
 Type of PVD – TechDrain : 100mmx 4mm
 Thickness of Clay layer : 8m to 12 m
 Grid Pattern : Triangular
 Spacing of PVD : 0.9m
 Preloading – Depending on Embankment height (6 to 10m)
 Time duration – Fixed based on preloading and allowable settlements (3 to 4
months)

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 GROUND IMPROVEMENT – PVD + PRELOADING

PVD
The Installation Rigdrain stitchers, can be
machine, called
either static or vibratory. The static
machines install the drain by pushing the
mandrel evenly into the ground, whereas
the vibratory machines drive the mandrel
with vibratory movement. Vibratory
machines are necessary particularly when
hard ground is to be penetrated. The
installation work of PVDs will be carried by
Saritha Infra.

45
GROUND IMPROVEMENT – PVD + PRELOADING

46
 GROUND IMPROVEMENT – PVD + PRELOADING
PVD Installation Procedure
STEP 1: STEP 2:
Remove any debris Place SQ1/Rock dust/Gravelly soil 0.3m
to 0.5m to have proper working platform
movement of equipment for installation
of PVD

47
 GROUND IMPROVEMENT – PVD + PRELOADING
PVD Installation Procedure
STEP 3: STEP 4:
PVD Installation Preloading Stage-1

48
 GROUND IMPROVEMENT – PVD + PRELOADING
PVD Installation Procedure
STEP 5: STEP 6:
Preloading Stage-2 Final Stage

49
 GROUND IMPROVEMENT – PVD + PRELOADING
Field Monitoring Devices:
 Casagrande Type Piezometers – 4 Nos each at 5000 sqm area
 Settlement Recorders – Plate Type 10 Nos each at 2000 sqm area

 Casagrande Type Piezometers: It is basically a porous tube

connected with the stand pipe. The pore pressure variation is
measured by measuring the variation in water level in stand pipe
Installation
 Recording of Data
To measure the water level in stand pipe electronic water level
indicator shall be used. The recorder sounds beep when the tip
of this recorder touches the water level. The depth can be
directly measured with the tape attached to this recorder. 50
 GROUND IMPROVEMENT – PVD + PRELOADING
Field Monitoring Devices:
• Plate Type Settlement Recorder: The Plate type settlement is
very simple recorder for measuring the settlement of virgin clay.
A pipe is connected to the square plate and the same shall be
placed on the virgin ground. The settlement shall be recorded by
noting the levels of top of the pipe attached to the base plate.
• Recording of Data
The settlement shall be recorded by noting the levels of top of the
pipe attached to the base plate. The levels shall be taken by any
regular survey instrument.
• Frequency of Records
 Weekly – When no loading is done.
 Every day - When loading is in progress.
 Weekly - After the loading is completed. 51
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THANK YOU
53