Finnish steel piling technology – Development and current practice Hannu Jokiniemi/Business Manager

Finnish steel piling
technology – Development
and current practice
Hannu Jokiniemi/Business Manager
Nordiskt Stålbroseminarium
1.10.2009 Stockholm
October 7, 2009
www.ruukki.com
Hannu Jokiniemi
Outline
• Introduction and history
• Application areas of the steel piles
• Product range of the steel piles
– Driven piles
– Drilled piles including background for Ruukki’s drilled piles and benefits
•
•
•
•
Material technology
Design and execution standards
Design & Long-term durability
Installation
– High capacities are easy to demonstrate for Large Diameter Steel Pipe Piles
• R&D today and in future
– Case movable railway bridges on large diameter drilled and driven steel piles
• Case histories
• Summary
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October 7, 2009
www.ruukki.com
Hannu Jokiniemi
Introduction and history
• Some individual minor projects in Finland in 1970’s
• Driven large diameter steel pipe piles in harbour structures in 1984
(Oritkari, Oulu)
– First master thesis related to steel pipe piles
• Driven large diameter steel pipe piles in bridges in 1987 (Kuokkala bridge,
Jyväskylä)
• Driven micropiles in 1987 (Kaukopää paper mill)
• Drilled large diameter steel pipe piles in 1997 (Tunnelipuisto underpass
bridge, Järvenpää)
• Today:
– Thousands of successfully executed job sites
– Over 20 master thesis and several licentiate and doctoral thesis
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October 7, 2009
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Hannu Jokiniemi
Application areas of the steel piles
• One-family and
terraced houses
• Residential and
non-residential
construction
• Construction of
bridges and
other traffic
infrastructure
• Harbour
construction
• Underpinning of
foundations
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October 7, 2009
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Hannu Jokiniemi
Product range – Driven piles
• Micropiles, RR75-RR220
• RR270-RR320-piles
• Large diameter piles,
RR400-RR1200
• Wall thickness 6.3-20.0 mm
• Element lengths 0.5-33.5 m
• Steel grades: S355J2H,
S440J2H, S550J2H, X60,
X65, X70, yield strength
355…550 MPa
• Workshop made
accessories: splices, rock
shoes, bottom plates,
bearing plates…
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October 7, 2009
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Hannu Jokiniemi
Drilled piles – Background
• Steel core piles have successfully been used in
the Nordic countries since 60’s
– soil conditions are favorable for end-bearing
piles
• Generally small diameter (D<300 mm) and wall
thickness (t<7 mm).
STEEL CORE
– the properties of drilling equipment and
techniques (eccentric drilling) have been
restricted the use of larger dimensions.
• The need for the higher bearing capacities,
stiffnesses and the development of the drilling
methods have led to gradually replacement of
steel core piles with the thick-wall drilled steel
pipe piles -> RD piles.
steel core pile
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October 7, 2009
steel pipe piles
www.ruukki.com
Hannu Jokiniemi
CEMENT GROUT/
GROUTING CONCRETE
CASING TUBE
RD piles
• RD piles (Ruukki, Drilling) are drilled end bearing steel
pipe piles in which steel pipe, concrete and possible
reinforcement are load bearing
Large diameter RD pile
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October 7, 2009
www.ruukki.com
Small diameter RD pile
Hannu Jokiniemi
Product range – Drilled piles
• Drilled steel pipe piles
RD90-RD800
• Wall thickness 6.3-16.0 mm
• Element lengths 1.0-16.0 m
• Steel grades: S355J2H,
S440J2H, S550J2H, X60,
X65, X70, yield strength
355…550 MPa
• Workshop made: Splices,
casing shoes, ring bits,...
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October 7, 2009
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Hannu Jokiniemi
RD piles – Benefits
• Extensive product range (length and
dimension)
• High bearing capacity
• High bending stiffness and moment
resistance due to the form of the crosssection
• Can be installed into all soil conditions,
even into rock surface
• Piles can be installed according to strict
position and inclination tolerances
• Piles can be inspected after installation
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October 7, 2009
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Hannu Jokiniemi
Material technology
• Modern steel piles in Scandinavia are manufactured from high steel grades
• Special steel grades (S440J2H and S550J2H) have been developed for
piling purposes
• Important properties: Strength, weldability and impact toughness
• Fatigue strength in mechanical splices
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October 7, 2009
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Hannu Jokiniemi
Design and execution standards
•
Finnish Road Administration
–
–
•
Association of Finnish Civil Engineers
–
–
•
–
11
Steel Pipe piles in railway bridges (FIN)
Ruukki
–
•
Instructions for high capacity piles (FIN)
Instructions for micropiles (FIN)
VR Track Ltd
–
•
Instructions for large diameter steel pipe piles (FIN,
ENG)
Instructions for drilled piles (FIN, ENG)
Instructions for RR piles (driven small diameter steel
pipe piles) (FIN, SWE, ENG)
Instructions for RD piles (drilled steel pipe piles) (FIN,
SWE)
Pålkommissionen
–
Pkr 84 & Pkr 96:1
–
Pkr 90 Grova stålrörspålar
–
Pkr 97 Stålkärnepålar
–
Pkr 98 Slagna slanka stålpålar
–
Pkr 102 Injekterade pålar
–
Pkr XXX Borrade stålrörspålar
October 7, 2009
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Hannu Jokiniemi
Design – European standards
• Structural
– EN1993-5: Piling
– EN 1994: Design of composite steel and concrete structures
• Geotechnical
– EN 1997-1: Geotechnical design. Part 1: General rules
– EN 1997-2: Geotechnical design. Part 2: Ground investigation and testing
– IEG Rapport 8:2008 TD Pålar
• Execution
– D<150 mm driven piles and D>300 mm drilled piles -> EN 14199 Micro Piles
– D>150 mm driven piles -> EN 12699 Displacement piles
– D>300 mm drilled piles -> EN 1536 Bored Piles ?
• Testing
– EN ISO 22477-1 Pile load test by static axially loaded compression
– EN ISO 22477-2 Pile load test by static axially loaded tension
– EN ISO 22477-4 Pile load test by dynamic axially loaded compression test
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October 7, 2009
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Hannu Jokiniemi
Design
P
• Structural design
– Steel or composite steel & concrete
design depending on the conditions
– Installed pile have certain initial
curavature
L
p=ksy
x
• Resistance of the pile cross-section
• Side resistance of the soil supporting pile
P
– Driving stresses
• Geotechnical design
– Classic static formulas for bearing
capacity
– Methods based on sounding
resistance
– Dynamic piling formulas
– Load testings: Static and dynamic
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October 7, 2009
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Hannu Jokiniemi
y
Design – Long-term durability
• Use of corrosion allowances for wall thickness is
the most often used method to consider corrosion.
• The latest recommendations are based on
statistical analysis of over 1600 observations of
steel objects in different soil conditions.
–
–
Observations contain Svenska Järnvägs corrosion
investigations
Recommondatios are similar to EN 1993:5
• The amount of corrosion is small in natural soil
conditions.
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October 7, 2009
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Hannu Jokiniemi
Installation – Driven piles
• Driving equipment
– Hydraulic hammers
– Drop hammers
– Pneumatic hammers
– Hydraulic rams
– Vibros
• Efficiency of the different equipment
has been increased during past 20
years
• Large diameter steel pipe piles can be
installed with relatively light piling
equipment to achieve high bearing
capacity -> verification of bearing
capacity by dynamic load testing
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October 7, 2009
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Hannu Jokiniemi
Example: Do we need heavy special
rig and hammer to install RR1000/12,5 for
>11 MN?
End of driving with HHK-7S
15000
kN
–
H=1.5m -> s=0.2 mm/blow
–
RMX = 6.9 MN
–
EMX = 81 kNm
F
BN 30
27.2.2004 9:32:25
EMX
81.6 kN-m
FMX
7633 kN
RMX
6939 kN
CSX
193.7 MPa
CSI
206.7 MPa
TSX
37.1 MPa
VMX
4.66 m/s
DMX
14.2 mm
FVP
1.00 []
9.28
m/s
V
25.6ms
4.40 ms
300.0
kN-m
50.0
mm
E
D
LE
11.35 m
AR
394.07 cm^2
EM 210000 MPa
SP
78.5 kN/m3
WS
5122.0 m/s
EA/C
1616 kN-s/m
F124
A12
F1: [] 95.3 (1.04)
F2: [] 95 (1.04)
F4: [] 95.6 (1.04)
A1: [] 1075 g's/v (0.95)
A2: [] 1055 g's/v (0.95)
25.6ms
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October 7, 2009
www.ruukki.com
Hannu Jokiniemi
Example: Do we need heavy special
rig and hammer to install RR1000/12,5 for
>11 MN?
PDA with 11.5 t drop hammer
15000
kN
–
H=5.0 m -> s=1.0 mm/blow
–
RMX = 14.8 MN
–
EMX = 307 kNm
F
BN 6
15.3.2004 15:27:01
EMX
306.7 kN-m
FMX
13549 kN
RMX 14751 kN
CSX
343.8 MP a
CSI
409.2 MP a
TSX
39.4 MP a
VMX
7.25 m/s
DMX
29.3 mm
FVP
1.00 []
9.28
m/s
V
25.6ms
4.40 ms
300.0
kN-m
50.0
mm
E
D
LE
11.35 m
AR
394.07 cm^2
EM 210000 MP a
SP
78.5 kN/m3
WS
5122.0 m/s
EA/C
1616 kN-s/m
F123
A12
F1: [] 94.3 (1)
F2: [] 94.7 (1)
F3: [] 97.4 (1)
A1: [] 1075 g's/v (1)
A2: [] 1087 g's/v (1)
25.6ms
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October 7, 2009
www.ruukki.com
Hannu Jokiniemi
Installation – Drilled piles
• Drilling rigs
– “Drill rig” based equipment
– “Excavator” based equipment
– “Piling rig” based equipment
• Drilling methods
– Centric drilling (Symmetrix,…) or
excentric drilling (Tubex,…)
– Reverse circular system
• Hammers
– Down-the-hole hammers (powered by
air or water)
– Top hammers
• Drilling methods to avoid soil
disturbance! (water powered drilling /
Wassara)
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October 7, 2009
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Hannu Jokiniemi
R&D today and in future
• R&D today is very customer-oriented
• Close co-operation between research
institutes, universities, consultants, owners
& authorities, contractors and material
delivers -> whole piling process
Geokohde 2007_2.pdf
• Some current and future R&D topics:
– Installation
– High strength steels and splicing
techniques
– Integral abutment bridge, soil-structure
interaction, continuous and jointless bridge
/ deck
– Connection between piles and upper
structures; footings (building construction)
– RD pile wall
– Long-term durability
– Energy piles
• Nordic co-operation
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October 7, 2009
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Hannu Jokiniemi
R&D case: Advanced construction
methods for railway bridges
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•
Demand set by the investor and by a passenger
•
R&D co-operation: Investors, designers, contractors,
material suppliers,…
•
New pile systems and transfer methods for bridge decks
October 7, 2009
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Hannu Jokiniemi
Example of connection between pile
and superstructure
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October 7, 2009
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Hannu Jokiniemi
Site views during the jacking of the deck
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October 7, 2009
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Hannu Jokiniemi
Infrastructure construction
Foundation Structures
Raahe Windpark, Finland
The foundation of the windmill is subjected to extremely high
overturning moment. Traditional solution is to use huge amount
of concrete as a foundation of the mill, which set challenges for
the construction during wintertime and for the environment.
The solution developed and demonstrated by Ruukki and it’s
partners in Raahe Windpark, utilizes modern drilling technology
of large diameter steel pipe piles and tension capacity of high
strength rock anchors. The solution is less dependent on soil
conditions and season and it is faster to construct.
Project features and Ruukki’s
delivery:
• Delivered in 2004
• First project ever where windmills are
founded on drilled steel pipe piles subjected
to extremely large compression and tension
loads.
• The solution enabled to decrease the
amount of concrete (-500 m3) essentially
and lead to shorter construction time. As a
result, 10% savings compared with
traditional foundation solution were realized.
• Ruukki’s delivery for foundations of 5 mills
consisted of 700 m drilled piles RD610/12,5
and 1,200 m drilled pipe anchors
RD220/12,5 in high-strength steel S550J2H
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October 7, 2009
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Hannu Jokiniemi
Partners:
• Contractor: Lemcon Oy
• Designer: PSV Maa ja Vesi Oy
• Client: ABB Oy and Suomen
Hyötytuuli Oy
Infrastructure construction
Road and railway construction
Vehmersalmi Bridge, Kuopio Finland
The arched steel girder bridge replaces the ferry service
and makes traffic flow more smoothly south of the City of
Kuopio.
The solution involving arched composite girders resulted in
an impressive bridge construction: long spans, short
construction time and overall economy. The longest span is
130 metres. The steel bridge is founded on steel pipe piles.
Project features and Ruukki’s
delivery:
• Bridge length 370 m
• Delivered in 2001
• About 1,400 tons of bridge girders
delivered
• 32 pcs steel pipe piles
RR900/14.2 with rock shoes, total
amount of piles 900 m
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October 7, 2009
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Hannu Jokiniemi
Partners:
• Contractor: Finnish Road
Enterprise
• Designer: WSP Consulting
• Client: Finnish Road
Administration
More information:
heikki.wilen@ruukki.com
Infrastructure construction
Road and railway construction
Lukkari Bridge, Pori Finland
The Lukkari composite girder bridge connects the
eastern and northern sections of the City of Pori.
The short construction time of this steel bridge solution
allowed implementing foundation and steel construction
work during the summer season.
The problem posed by the very difficult founding
conditions was solved by using steel pipe piles and a
lightweight composite construction.
Project features and Ruukki’s
delivery:
•
•
•
•
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October 7, 2009
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Bridge length 200 m
Delivered 2004-2005
About 550 tons of bridge girders
16 pcs steel pipe piles
RR900/12,5 with rock shoes,
total amount of piles 850 m
Hannu Jokiniemi
Partners:
• Contractor: Finnish Road
Enterprise
• Designer: Ramboll Finland Oy
• Client: Municipality of Pori
More information:
heikki.wilen@ruukki.com
Infrastructure construction
Road and railway construction
E 18 Muurla-Lohja motorway, Finland
50 km long motorway section from Muurla to Lohja has
been constructed since 2005 and it will be ready in
2009. The E 18 motorway section is the missing part of
the Highway 1 between Helsinki and Turku. E 18 project
is the biggest road project in Finland of all-time.
Ruukki’s wide ranging delivery to this huge project
includes 142 km of guard rails, load bearing steel
structures for five bridges and 4,5 km of steel pipe piles.
Project features and Ruukki’s
delivery:
• Ruukki’s deliveries 2006 - 2008
• Total quantity of guard rail
systems 142 km
• Total quantity of load bearing
structures for bridges 2,390
tons
• Total quantity of steel pipe piles
4,5 km
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www.ruukki.com
Partners:
• Contractor: Several
• Client: TYL E 18
More information:
info.construction@ruukki.com
Infrastructure construction
Road and railway construction
Mälkiä Canal Bridge, Finland
Mälkiä canal bridge crosses the Saimaa canal in
Lappeenranta. The bridge will be 315 m long and it is part of
the development project of the motorway between
Lappeenranta and Imatra. The project will be completed at the
end of 2010.
Ruukki’s delivery includes bridge superstructures and steel
pipe piles fitted with rock shoes for the foundations of the
bridge. The installation of the surface treated steel structures
is also included to the delivery.
The prefabricated elements minimize the construction time
and make the demanding time schedule possible. The close
cooperation with designers and contractor creates a reliable
and flexible partnership.
Projects features and Ruukki’s delivery:
Partners:
• Investor: Tiehallinto
• 315 m long bridge crossing Saimaa-canal
• steel pipe piles fitted with rock shoes
• supplying and installing surface-treated
steel structures
• will be completed at the end of 2010
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October 7, 2009
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Hannu Jokiniemi
• Main contractor: Consortium
TYL Vt6
• Designer: Sito Oy
More information:
hannu.rautakoski@ruukki.com
Summary
• Steel is feasible material with many suitable
properties to be used in piling applications especially
for bridge foundations.
• Intensive R&D related product range and piling
methods under during last 20 years
– The pleasant issue in the R&D has been the co-operation
between different parties
• The current product range offers a competitive
solution for nearly every possible soil conditions.
– The current general trend seems to be from “driving” to
“drilling” and today in Finland RD piles have replaced steel
core piles nearly totally.
• There are still markets for new ideas and further
development.
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October 7, 2009
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Hannu Jokiniemi