combined jdm-sh-akb - pbe presentation by golder, hyder & scott wilson

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    Monday, 18 April 2011, 5:30 pm for 6:00 pm start

    All welcome. Food and drinks served at 5:30 pmAbstract:

    The A$500M Sydney Ports Corporation Third Container Terminal at Port Botany required: dredging ofmore than 10 million m3of material, more than 60 Ha of reclamation and the construction of over 2 km ofquay wall to accommodate Post Panamax container terminal vessels and tug berths.

    This project was delivered as part of a Design and Construct Project joint venture between BaulderstoneHornibrook & Jan De Nul and a design consortium comprising: Hyder Consulting, Scott Wilson andGolder Associates which involved designers in local, national and international locations.

    This joint presentation from the three main contributors of the design consortium will discuss thesignificant engineering challenges involved in this project and the details of the final engineering designadopted. The presentation will cover the full spectrum of civil and structural design, maritime andgeotechnical engineering.

    NSW Maritime Panel presents

    Port Botany Expansion Quay Wall Design and Construction

    byAlan Betts (URS/Scott Wilson)

    Sam Harris (Hyder)Jamie McIlquham (Golder Associates)

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    The presenters:

    Sam Harris: Maritime Manager Hyder Consulting LtdJamie McIlquham: Senior Geotechnical Engineer Golder Associates,

    Alan Betts: Australian Maritime Manager URS/Scott Wilson

    Sam has experience in the project management, investigation, planning, design and constructionsupervision of port and maritime infrastructure projects in Australia, UK, Nigeria, Ireland, Mauritius,Kuwait, Libya and UAE. Sams role on this project has been as the Marine Design Manager for the D&Cconsortium.

    Contact:[email protected]

    Jamiehas 12 years of experience working on geotechnical projects in Australia, the UK and Gibraltar.During the Port Botany Expansion project he was in charge of several design packages including thedredging and reclamation works and geotechnical design of caisson structures. During construction heled the geotechnical team and provided ongoing geotechnical advice and supervision.Contact:[email protected]

    Alanhas more than 30 years of experience in the planning, design, construction and maintenance of port

    and harbour works, in Australia, NZ and other overseas locations. Alan undertook local preliminaryengineering design and peer review of many of the design elements for this project.Contact:[email protected]

    mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]
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    Geotechnical Design of Quay Structures

    for the Port Botany Expansion (PBE)Jamie McIlquham - Senior Geotechnical Engineer -

    Golder Associates

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    Introduction

    Geotechnical Model

    Design Requirements

    Desi n Solution

    Introduction

    April 19, 2011 2

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    63ha Reclamation

    2km of New Berth Structures

    New Navigation Channels and Basins

    Brid es, Breakwaters, Future Rail Corridor,

    Summary of PBE Project

    Revetments

    April 19, 2011 3

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    Site Location

    April 19, 2011 4

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    Geotechnical Model

    April 19, 2011 5

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    Quaternary sediments up to 80m thick over HawkesburySandstone

    Four basic soil units: Unit 1 recent estuarine deposits, loose

    Unit 2 clean sand, dense to very dense, peat and clay

    Geotechnical Model

    Unit 3 mainly organic clay, very stiff to hard, fissured

    Unit 4 clay, very stiff to hard, some fissuring and less

    organic content than Unit 3

    Soils are highly discontinuous laterally.

    April 19, 2011 6

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    Geotechnical Model

    April 19, 2011 7

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    Section showing Dredging and Reclamation

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    Section showing Counterfort and Reclamation

    RL+4mCD

    Unit 2 Sand

    Upper Reclamation Fill

    Lower Reclamation Fill

    Unit 2 Sand

    Front Crane Rail Rear Crane Rail

    RL-17.5mCD

    Counterfort

    Structure1m Scour Protection

    Cope Beam

    RL-10mCD

    35m

    CounterfortBackfill

    April 19, 2011 9

    Unit 3 Clay

    Unit 4 Clay

    Unit 3 Clay

    Unit 6 Sandstone Bedrock

    Trench Backfill

    0.8m Thick Basal Trench

    Rock

    Base of Trench at RL-30mCD

    1m Thick Foundation

    Pad

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    Construction Sequence

    1

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    Construction Sequence

    2 30

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    Construction Sequence

    3 13.5

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    Construction Sequence

    4

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    Construction Sequence

    5

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    Construction Sequence

    6 +3.5

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    Construction Sequence

    7

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    Construction Sequence

    8 300/ 3

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    Construction Sequence

    9 90 ( +2.5) 1

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    Construction Sequence

    10

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    Construction Sequence

    11

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    Construction Sequence

    12 +4

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    PSTR - design requirements

    Stability Criteria

    Serviceability Criteria

    Loadin Information Onl for PBE

    Design Requirements

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    Design Solution - Trench Foundations

    Removal of fissured clay required to RL-30mCD over1680m out of 1850m of main berth length (Approx 0.8Mm3 )

    Strength and stiffness of backfill controlled by stability and

    movement criteria for PBE berth structures

    Target backfill stiffness: Secant Modulus (Es) 100MPaat a reference confining pressure of 100kPa; and

    Target strength: friction angle () of 37

    Stiffness generally dictated amount of compaction

    Trench size was then optimised to provide the required

    stability performance, taking into account dredgingtolerances

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    2D PLAXIS

    SLOPE/w

    Spreadsheets - Sliding, Overturning &Bearing Capacity

    Design Solution Analysis Methods

    Collaborate (Match Geotechnical & StructuralModels)

    Communication (Internal & External)

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    Stability criteria were:

    Sliding & Overturning FoS > 2.00

    Bearing Capacity FoS > 3.00

    Global Stabilit FoS > 1.40 / 1.50

    Design Requirements - Stability

    Seismic (Sliding & Overturning / Global) FoS > 1.10

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    Stability Assessment

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    Serviceability criteria were most critical:

    Vertical settlement

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    Backanalysis of EBD counterforts to selectdeformation parameters

    Laboratory testing, design of EBD andstatistical assessment were also considered

    Design Solution - Serviceability

    Sensitivity analyses completed to checkpotential impacts

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    PLAXIS used to assess movement and earthpressures acting on the structures

    Staged construction in model

    Design Solution - Serviceability

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    Pressures derived from PLAXIS analyses

    Geotechnical models calibrated against structural models initerative process

    Counterforts

    Ka at shallow depth

    Lateral Soil Pressures on Wall Structures

    0

    Blockwork caissons tend towards full depth K0 profile

    April 19, 2011 31

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    Seismic Bearing Capacity

    Vibrocompaction next to structures

    Design Solution

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    Seismic Bearing Capacity

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    Conventional Limit Equilibrium seismic bearing capacitysupplemented with displacement based criteria

    Assessed using dynamic PLAXIS analysisSimilar movement mechanism to port caisson units afterKobe Earthquake

    Seismic Bearing Capacity

    Local yielding at toe and heel Minimal settlement

    Seaward translation

    Analysis results can be compared to performancerequirements

    April 19, 2011 34

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    Seismic Design

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    Need to control earth pressure to limit serviceability designfor concrete durability

    Need to balance compaction required for backfill strengthand stiffness against earth pressures

    Conceptual Soil Stress Path for PBE wall backfill:

    Effect of VC on Wall Structures

    0 ,

    Increased horizontal earth pressures due to VC, no arching

    Relief during/after compaction to Ka as the structure moves

    K0 remains in trapped wedge

    Design VC probe offset based on published data effects Site trials necessary to assess impact of VC

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    Effect of VC on Wall Structures

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    Field trials using V48VC Rig

    Eccentric force 230-

    470kN @ 60Hz

    Trials completed

    Effect of VC on Wall Structures - Trials

    Sheet pile wall Caisson structure

    Counterforts

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    Effect of VC on Wall Structures - Trials

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    Counterfort Compaction Trial

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    Revised compaction method (Grid Typ. 3.6-4.2m)

    Full Energy

    40 Secs compaction per 1m lift; or400 Amps drawn by motor

    Reduced Ener

    Effect of VC on Wall Structures - Trials

    20 Secs compaction per 1m lift; or300 Amps drawn by motor

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    Revised Compaction Criteria

    April 19, 2011 42

    Eff f VC W ll S T i l R l

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    Final profile closely matches predicted PLAXIS

    profile for wished into place fill

    Earth pressures were consistent with wallmovements

    Peak transient ressure hi h durin VC 1-1.5 x K

    Effect of VC on Wall Structures Trial Results

    but

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    Managed Earth Pressure Risk by:

    Considering alternative compaction equipment

    Adopting reduced energy VC points within 2.5m ofwall

    Revising compaction criteria behind structure

    Effect of VC on Wall Structures Trial Results

    Verification of assumptions with earth pressurecells and survey

    Important to consider sequence of VC locations,particularly in confined locations

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    Dredging Hydrographic survey Dec 2009

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    Dredging Hydrographic survey Dec 2009

    Information provided by PB (Project Verifier)

    Dredging Hydrographic survey Mar 2010

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    Dredging Hydrographic survey Mar 2010

    Information provided by PB (Project Verifier)

    Dredging Hydrographic survey Aug 2010

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    Dredging Hydrographic survey Aug 2010

    Information provided by PB (Project Verifier)

    Thank You

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    Jamie McIlquhamSenior Geotechnical EngineerGolder Associates124 Pacific HighwaySt LeonardsNSW 2065 Australia

    Thank You

    Tel: +61 (0) 2 9478 3900Mob: 0422 538155

    E-Mail: [email protected]

    Web: www.golder.com

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    Port Botany Container Terminal Expansion Quay Wall D&C

    Date: Monday 18thApril 2011Presented By: Sam Harris

    Presentation Overview

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    Project Summary Project Team

    Key Client Performance Criteria

    Confidence in Concrete

    Design Approach Chloride Diffusion Modeling

    Concrete Mix Design

    Concrete Quality Control

    Limit States Design Approach

    Counterforts

    Landward Crane Beam

    Other Aspects

    Project Summary

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    $1B development (including 3rd terminal operator investment)

    1855m long by -16.5m CD deep container quay

    199 counterfort units

    4 segmental block caissons

    157m long by -7m CD deep tug berth

    17 counterfort units Total 90,000m3 concrete

    Total 15,000t steel

    >11M m3 dredged material

    63Ha terminal reclamation (8.4M m3

    ) Foreshore enhancement and road/service works

    Navigation aids

    Terminal development by future operator (rails, pavements, buildings,internal terminal services etc)

    Comparison PBE site before and almost complete

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    Port Botany Expansionbefore September 2008

    Port Botany Expansionin December 2010

    Project Team

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    Technical Advisers to SPC

    Lead Design Consultant

    Maritime DesignSub-Consultant

    Geotechnical DesignSub-Consultant

    D&C Contractor

    Client

    3rd Terminal Operator

    Project Verifier

    Key Client Performance Criteria

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    100 year design life

    Confidence in durability with minimal maintenance Tight lateral and vertical movement and rail gauge limits

    Post-Panamax vessels

    8000TEU & 106,000DWT

    347m LOA 46m beam

    14.5m loaded draft

    Design crane loads

    120t operating wheel loads

    8 wheel bogie set

    1900t crane dead load

    120t bollards

    40kPa between rails/ 60kPa in yard stacking surcharge

    Counterfort Structure

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    Confidence in Concrete

    Reinforced concrete = cost effective

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    High level of assurance in achieving durability requirements

    Mouldability

    Plant available economically

    Precast modular construction

    Fabrication/batching on site Use of recycled materials

    Local concrete products

    Construction skills relatively

    straightforward and local

    Quality control relatively simple

    Lends to gravity type structure

    Confidence in performance only if a well managed and informed

    design process is followed

    Exposure Classifications

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    Design Approach

    Chloride Diffusion Modelling

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    g

    Differing approaches to durability in various Australian Standards Chloride Diffusion Model (Luping and Gulikers) is key to 100 year

    design life:

    The model considers:

    Chloride concentration threshold at the

    reinforcement for the initiation of corrosion Cover

    Surface chloride concentration

    Rate of chloride diffusion

    Time to onset of corrosion

    Design Approach

    Concrete Mix Design

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    Concrete Mix Design

    Zone 1 mix: Continuously submersed or buried Medium level chloride diffusion coefficient

    (D= 5.2 x 10-12 m/s)

    Medium level drying shrinkage (600x10-6)

    50MPa

    52%SL, 25% Fly Ash, 23% Blast Furnace Slag

    600kg/m3 cementitious content

    0.38 w/c ratio

    Zone 2/3 mix: Tidal splash zone

    Lower level chloride diffusion coefficient

    (D=3.4 x 10-12 m/s )

    Lower level drying shrinkage (500x10-6)

    Zone 1 mix used for Zone 4 (low risk)

    Design Approach

    Concrete Cover

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    Design Approach

    Concrete Quality Control

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    Boral on site batching plant On site precast yard

    Concrete mix approval process

    Quality Assurance processes

    Independent surveillance

    Steel formwork used seaward face

    poured face down on vibrated formwork

    28 days wax based curing compound before placement in water

    Assurance Through Design Detailing

    Seaward face = compression face

    Joint between wall and base component in compression

    Design Approach

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    Limit State Design Approach Appropriate Loads & Combinations

    Key Design Loads:

    Construction Loads

    Ciria C660 Early Age Thermal

    Lateral earth pressure

    Lateral berthing and mooring loads

    Vertical and lateral crane loads

    Seismic

    Combinations:

    Construction Loads Quasi-Permanent/Sustained Loads

    Transient Load Combinations

    Ultimate Load Combinations

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    Design Approach

    Calibration of Soil/Structure Interaction

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    Plaxis 2D FEASoil/Structure Model

    Strand7 3D FEAStructural Model

    Strand7 and Plaxis

    Deflections Consistent

    Apply Lateral Soil Loadsin Structural Design

    YES?

    NO?

    OUT:

    Soil Pressure

    Deflections

    OUT:

    Deflections

    Design Approach

    Serviceability Limit State

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    Quasi-Permanent/Sustained Load CombinationsDL + Permanent Soil Loads + Sustained Crane Load + Sustained Surcharge Load

    Flexural/Tensile Crack Width Assessment & Mapping

    0.3mm Max for Zones 1 and 4

    0.2mm Max for Zones 2 and 3

    Limiting Bar Stress

    AS3600 limits for Zones 1 and 4 (280MPa Typ)

    AS4997 limits for Zones 2 and 3 (150-180MPA Typ)

    Transient Load Combinations

    DL + Permanent Soil Loads + Op Crane Load +

    Op Sustained Surcharge Load + Mooring/Berthing

    400MPa Limiting Bar Stress Remain in elastic range

    Ultimate Limit State

    Counterfort Details & Construction

    Details:

    U it W i ht 640t

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    Unit Weight = 640t

    Concrete/Unit = 245m3 Steel/Unit = 52t 20m tall 9m wide 15m base length 2 buttresses 216no

    Trench Foundation to -30m CD

    Vibrocompacted reclamation fill

    Vertical grout bag & temporary flexible

    seals between units

    3D PDFWall to base

    joint detailSea Side

    FlexibleMembrane

    Counterfort Details & Construction

    Counterfort Precast Facility

    http://localhost/var/www/apps/conversion/tmp/scratch_2/XS3D-COPEBEAM-ARRANGEMENT-NS.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_2/XS3D-COPEBEAM-ARRANGEMENT-NS.pdfhttp://localhost/var/www/apps/conversion/tmp/scratch_2/XS3D-COPEBEAM-ARRANGEMENT-NS.pdf
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    Ringer Crane

    Reo Prefab on Outer Ring

    4 Base Forms

    4 Wall Forms

    5 Assembly Beds

    Sheds cover

    base and

    wall forms

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    Counterfort Details & Construction

    Counterfort Storage/Transport

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    Counterfort Storage/Transport

    ...and Placement

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    Continuous Beam Design

    D i P t E i

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    Why Design Beams Continuously?

    1) Improved load distribution

    2) The expansion joint arrangements are complex

    3) Rigid foundation results in a near continuous

    condition

    Tension Inducing Factors

    1) Shrinkage

    2) Thermal contraction (time series &

    steady state thermal analysis)3) Construction sequence (stitch location/timing)

    Drawing on Past Experience:

    Hyder design of Dubai Festival City

    Building had a 650m long x200m wide basementconstructed without expansionand contraction joints and

    supported by piles. Basementrequired to be water tight.

    Foreshore Enhancement Works

    Penrhyn Estuary reprofiling & improvement works

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    Landscaping Revetments and breakwaters

    Boat ramp

    (incl. navaids, wash down and fish cleaning)

    Mill stream lookout

    Footpaths

    Amenities building

    Car parks

    Road and Utility Works

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    Terminal access bridge Pedestrian bridge

    Foreshore road works

    Service supply works:

    Electrical

    Lighting

    Water

    Sewer

    Comms

    Stormwater

    Acknowledgements

    Thanks to:

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    Sydney Ports Corporation

    Baulderstone & Jan de Nul

    Golder Geotechnical Design Sub-Consultant

    Scott Wilson Maritime Design Sub-Consultant

    Thank You

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    Sam Harris

    Deputy Director Ports & Maritime Australasia

    Hyder Consulting Pty Ltd

    Level 5, 141 Walker StreetNorth Sydney NSW 2060 Australia

    Mobile: 0429 535 283

    Direct: +61 (0) 2 8907 3966

    Fax: +61 (0) 2 8907 9001

    Email: [email protected]

    Web: www.hyderconsulting.com

    mailto:[email protected]://www.hyderconsulting.com/http://www.hyderconsulting.com/mailto:[email protected]
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    Presented by: Alan BettsDate: 18/4/2011

    For: NSW Maritime Panel

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    The presentation covers structures other than the counterfortretaining wall units and the landward crane beam and geotechnical

    considerations (covered by others), including:

    Blockwork Structures

    Brotherson Dock Transition

    Cope Beam

    Fenders/ Bollards/ ladders

    Navigation Piles

    Main Berth Scour Protection

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    4 main blockwork structures:

    North West and South West Corner Blocks

    Brotherson Dock Transition Block

    Brotherson Dock Infill block

    Component maximum weight 630 tonnes

    Same concrete mix and cover as for counterforts

    Similar foundation as for counterforts

    Sand backfill, vibro compacted, kentledge and sand surcharge as forcounterforts.

    Horizontal and vertical grouted seals + horizontal butyl seals betweenelements

    Grouted vertical bars tying units together on seaward faces

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    Design loads similar to counterforts

    Analysis undertaken using:

    Microstran and Finite Element Analysis - using Strand 7

    SlopeW used to assess global stability

    Plaxis used to assess soil pressures and wallmovements

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    BDT, SW corner and NW corner caissons: Segmental structures: 4 cells, 4 high, shear keys in internal and external walls

    BDT Infill Block work Structure: Segmental structures: 2 cells, 7 high, shear keys in internal and external walls

    Partial reinforcement cage prefabrication

    Peri formwork system

    Each block constructed in 2 pours

    Transported and placed with shear leg barge

    Diver assisted grout bag joint seals External wall thicknes: 400mm

    Internal wall thickness: 500mm

    Base thickness: 500mm

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    Need to modify existing structure to accommodate the new quay crane railloads and the transition beam. Involving:

    Removal of existing wharf bollards/ fenders/ part cope beam

    Jet grout of south west cell for ground improvement Part block work demolition works Construction of transition beam

    landing pad and anchorage

    Reinstatement of cope beam Installation of transition cope

    beam Reinstatement of bollards/

    fenders/ crane rail/ crane buffer

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    Blockwork structures required to make transition betweenthe existing and new structure, including:

    Modification to existing BDT caisson, including groundimprovement within cell

    New 4 cell

    15m long transition beam: 900mmx800mmx105mm elastomeric base bearing 4no.

    170mmx350mmx80mm elastomeric buffer bearings 6no. Deadman anchors on BDT blockwork structures to control

    differential movement limits/crane continuity

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    Construction sequence: Dredge and place bedding

    Place larger BDT caisson structure

    Fill up to 0.5m below base of infill blocks Place base infill block on temp supports and concrete beneath

    Finish placing infill blocks

    Place adjacent counterfort units

    Infill blocks, backfill and vibrocompact

    Surcharge and kentledge loading

    Install deadman anchor system

    Grout vertical grout bags and seaward face horizontal seals

    Install vertical anchor bars and grout up

    EBD caisson improvement works Cope beam construction and fill to final levels

    Transition cope beam construction and installation

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    Anchors required for stability of new BDT block & infill block

    Located 5m landward of landward crane beam

    Concrete anchor: Total length 17m, consists of precast sectionsapprox. 6m long x 2.5m high x 0.6m thick.

    Tie rods McAlloy bars:

    Particular provisions for corrosion protection and tie rod settlement

    - 50mm dia. Approximately 33m length, sections joined with couplers,Densopol 60 covering, plus annular concrete duct, all placed at baseof 300mm dia settlement duct.

    Level of tie rods; approx mean sea level

    Tie rods for transition block go through blockwork rear wall

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    Typical deadman anchor details

    Typical detail through caisson wall

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    Transition Beam provides forarticulation of foundations (1 in1000 grade limit for crane rail)

    Beam weight approx. 350 tonnes,14 m long, supports front containercrane rail

    Four main support bearingslaminated rubber elastomeric, twoat each end

    Six side bearings, three at each end

    Bearings consist of rubber andstainless steel plates.

    Design allows for main bearingreplacement using flat jacks andmanhole access at land side

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    Plan on beam Plan on side bearings

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    Total length over 2km: 650m EW berth, 1300m -NS berth,-150m tug berth (no jointsother than construction)

    Consists of combination of precast and cast in-situ concrete elements

    Precast elements comprise the front face of the beam. 120 tonne bollards @ 24m spacing

    Cell fenders @12m spacing (Shibata CSS 1450H) with frontal frames

    Crane rail and cable slots

    Stowage pin rebates at 30m centres

    Blockouts for crane end stop buffers

    Type F Gatic covers for service pits

    Designated quay crane delivery and maintenance areas

    Cope level of +3.65mCD for EW berth and +4.0mCD on NS berths

    Service pits; Shore Power Supply Pit (SPSP), Crane Cable Pit (CCP), Water Pit (WP)Cope Beam Section Size Depth Width

    NS Berth 1.5m 3.2m

    EW Berth 1.5m 3.41m

    Tug Berth 1.5m 2m

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    Cast monolithically with quay structure below to allow direct transfer of loadsto supporting quay structure

    Cast in-situ beam carries primary longitudinal bending in the cope beam as itacts to distribute loads along its length

    Typically 117 N32

    Longitudinal bars

    Counterfort Starter Bars

    Precast Starter Bars

    Counterforts and trench foundation relyon cope beam to distribute loading

    Vertical Loads:

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    Vertical Loads: Crane loading

    Vertical bollard loading

    Vertical fender loading

    Differential settlement Crane delivery and maintenance

    Vehicle loads (e.g. reachstacker)

    Horizontal Loads: Bollard loads

    Fender loads

    Crane loading

    Post cope beam construction soil loads

    Seismic loading

    Differential movements

    Shrinkage

    Thermal loading

    Load combinations

    Design Analysis

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    Design Analysis

    Microstran/SAP 2000/Strand 7 used for the cope beam design

    Design for coincident design actions from worst case combinations

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    Precast formwork on front faceTypical Section

    Additional precast formwork for crane cableservice pit

    Cope beam needed to be significantly widened at the corners and

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    NW Corner SW Corner

    Cope beam needed to be significantly widened at the corners andBrotherson Dock Transition to tie all units together and for seismic stabilityconstraints

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    SW Corner Cope Beam Under Construction ~670m3 of Concrete ~200t of Steel

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    Summer Winter

    60 Days 14 Days 60 Days 14 Days

    TypicalSection

    Jacking CCP StitchTypicalSection

    Jacking CCP StitchTypicalSection

    Jacking CCP StitchTypicalSection

    Jacking CCP Stitch

    EW

    Top 41 42 38 51 44 45 38 51 36 36 34 42 37 37 34 42Bottom 38 42 35 48 41 46 35 48 34 36 32 42 35 36 32 42

    Landward 16 16 19 23 20 20 25 23 16 16 17 16 16 16 19 16

    Seaward 16 16 22 25 22 22 26 25 16 16 17 17 16 16 19 17

    TOTAL 111 116 114 147 127 133 124 147 102 104 100 117 104 105 104 117

    NS

    Top 40 40 36 52 43 45 41 52 35 35 33 44 36 36 33 44

    Bottom 35 40 31 46 37 47 38 46 33 33 31 40 34 34 31 40

    Landward 16 16 20 22 19 19 22 22 16 16 16 16 16 16 17 16

    Seaward 17 17 22 25 21 21 24 25 16 16 16 17 16 16 17 17

    TOTAL 108 113 109 145 120 132 125 145 100 100 96 117 102 102 98 117

    Length of each pour: ~33m

    Length of stitch pour: 3m

    Stitches generally occur above counterfort joints. Reinforcement varied according to summer or winter

    temperature and duration between pours

    All bars are N32

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    Element LocationHeight(m)

    Depth(m)

    Thickness(m)

    ApproximateSteel Reinforcement/Concrete Volume

    (kg/m3

    )

    Cope Beam

    NSTypical 1.5 3.2 195.5

    Stitch 1.5 3.2 244.2

    EWTypical 1.5 3.41 204.2

    Stitch 1.5 3.41 248.6

    Landward Crane

    Beam NS

    Beam 2 1.5 302.6

    Pile 0.9 354.4Cope BeamPrecast Unit

    NSFender Block 192.8

    SPSP 261.8

    Counterfort NS

    Base 8.92 14.368 0.3 318.7

    Wall 17.64 8.92 0.35 169.7

    Buttress 18.8 10.313 0.35 174.5Corner Blockwork SW

    Base Slab 16.248 14.667 0.5 290.4Unit24 Seaside Wall 5.78 12.75 0.4 175.6

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    Crane rail not installed (stevedore to supply) Blockouts (40mm dia. x 260mm long)

    provided for 24mm dia. crane rail bolts Stainless Steel (grade 316) Edge Protectionfor concrete at crane cable slots

    Construction following all quay wall and earthworks processes

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    g q y p

    Limited work above/next to water

    Shelf between counterfort corbels provides part of the base formwork

    Precast front elements comprise the seaward form

    Temporary Precast

    Support

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    Cope beam precast standardised to facilitate mass production

    North South berths 6 types & 140 units

    East West berth 5 types & 51 units

    Reinforcement connectivity provided with cast in-situ cope beam

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    168 rubber fenders (Shibata CS 1450 circletype) with frontal frames, 2.3m wide x 3.5m high. Aluminium anodes at low level on frames Galvanised chains Stainless steel u-bolts for fender restraint/

    support chains in concrete cope beam

    Ultra high molecular weight polyethylene facingpanels on frontal frames varying sizes, 40mmthick

    Fenders at 12m spacing but closer at ends

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    Installed Fenders NS Berth.

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    Cast Steel Bollards

    Finite Element Analysis design and

    load tested Hollow, concrete filled,& painted

    Stainless steel (316 grade) bollardbolts

    Special cap and epoxy masticfilling around nuts

    Bollards generally installed at 24mcentres with provision for future

    installation with recesses and boltblockouts.

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    3 off

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    3 off

    Piles 965mm OD and 16-20mm wallthickness

    Typical embedment depth: 15.5-18.5m

    Nominated vessel impact: 50% energyof 5 tonne vessel travelling at 3m/s.

    Corrosion protection:

    Denso Seashield 100 systemextend to - 0.5 m

    2 Aluminium anodes at lower level(-0.5 m to -1.7 m)

    Aluminium superstructure platform

    (isolated from steel) Aluminium ladder with hardwood

    fenders.

    Scour Armour Rock

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    TypeMass

    Mmin (kg) M50 (kg) Mmax (kg)

    S1 150 300 600

    S2 28 76 159

    Basalt rock, 2.65 t/m

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    Stringent specification toavoid degradation

    Two main rock gradingsizes, largest adjacent toquay

    Extends 15m from quay wall

    Thickness varies from 0.6mto 1.0 m

    Placed on geotextile fabric,Geomac 500E

    Fabric placed with purpose-built frame to avoid diverplacement

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    Frame used to place geotextile

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    Thanks to:

    Sydney Ports Corporation

    BHJDN

    Hyder Consulting Lead Designer

    Golder Associates Geotechnical Design Sub-Consultant

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    Acknowledgements:

    Presentation compiled by: Kenan Aldemir Maritime Engineer Sydney

    Heli Lhteel Project Administrator Sydney

    Reviewed by Alan Betts Questions and inquiries to Alan Betts: Contact details:

    Email: [email protected]

    Telephone +612: 8925 5545