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Building the Foundations of Australia

Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast. Presentation EXTREME COMPRESSION AND TENSION LOADS FOR THE SOUL TOWER, A 77 STOREY APARTMENT BUILDING ON THE GOLD COAST 12th May 2010, 9.15 pm IQPC Piling & Deep Foundations Conference Melbourne

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Building the Foundations of Australia

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  1. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Presentation EXTREME COMPRESSION AND TENSION LOADS FOR THE SOUL TOWER, A 77 STOREY APARTMENT BUILDING ON THE GOLD COAST 12th May 2010, 9.15 pm IQPC Piling & Deep Foundations Conference Melbourne Hotel Bayview Eden, Melbourne Speaker: Martin Larisch (Piling Contractors) Building the Foundations of Australia www.pilingcontractors.com.au

  2. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Site location of Soul in Surfers Paradise, QLD

  3. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Finished appearance in Surfers Paradise, QLD

  4. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Site location of the project in Surfers Paradise, QLD

  5. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Introduction: About the Soul Project • 77 storey apartment building with a retail area surrounding the main tower • Third highest residential building in Australia (277m) • Beach front location in the heart of Surfers Paradise • Demolition works started in December 2007, proposed completion of the • project mid of 2011 • Main Contractor of the D&C project is Grocon Constructors (QLD) Pty Ltd • Piling works awarded as D&C package to Piling Contractors Pty Ltd in • December 2007

  6. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Introduction: Early Site Investigation • Developer employed McConnell Consulting in 2005 to carry out a soil investigation comprising 4 boreholes with SPTs and undisturbed sampling in soils and NMLC triple tube coring in rock • Point load index tests on rock samples • Classification tests on soil samples • Noted that the concept was for a very tall structure with unusually deep basements

  7. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Introduction: Site Investigation used for pile design • Grocon employed Golder Associates in 2007 to review Site Investigation and make recommendations: • Data from this site and two adjacent sites considered in new report • Suggestion of ranges of UCS and Modulus • Use of ROCKET to determine ranges of shaft friction • Base resistance greater than available concrete strength • Recommendation of additional drilling

  8. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Introduction: Piling works Pile installation was carried out in four stages from January – Sept. 2008

  9. Stage IV CFA piles 09/2008 Stage III CFA piles 05-07/2008 Stage I CFA piles 01/2008 Stage II tower piles 03-08/2008 Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Pile layout plan - Pile installation

  10. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Pile layout plan - Location of tower piles Tower piles

  11. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Bored piles for the main tower • 44 large diameter bored piles (installed under bentonite) for the main tower • pile cut off levels 9m & 14m below working platform • plunged steel columns required for 21 piles • pile Ø 1500mm, 1800mm and 2200mm • drilling depths up to 45m

  12. 1500mm 1800mm 2200mm Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Pile Layout Plan - Pile diameters tower piles column

  13. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Site Geology - Site location of Soul in Surfers Paradise, QLD

  14. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Site Geology - Assumed soil profile Typical site conditions detailed in the chart below:

  15. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Site Geology - Further Site Investigation by Grocon / Golder • One additional borehole drilled to 42m depth (-44.5m AHD) • Results confirmed previous investigation • Pile bases had to be very clean to mobilise end bearing • 100% requiring a comprehensive cleaning system and SID • Some base debris, requiring sweep airlift and purpose built cleaning buckets; bentonite with <2% sand content • Shaft friction only, requiring conditioning of drilling fluid and cleaning bucket

  16. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Site Geology - Assumed soil profile

  17. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Site Geology - Summary point load tests

  18. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Site Geology - Design parameters • Point load tests from two independent soil investigation reports indicate • high strength to very high strength Argillite in the target founding zone for pile toe levels • Piles to be designed with rock sockets of at least one pile diameter into • high strength Argillite or better (UCS between 20-30 MPa) • Piles with high tension loads to be designed and constructed with longer rock sockets of 3.5m

  19. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Site Geology - The following parameters were recommended:

  20. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Site Geology - Geotechnical design by Piling Contractors • Piling Contractors appointed PSM to carry out geotechnical design review • Examined soil profile • Carried out FE modelling • Minor modifications to socket length suggested and accepted by MJ Civil • Looking at settlement and differential settlement, and at tension capacities

  21. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Building loads for the Soul tower • Vertical compression load of building (MN) • Vertical tension load (MN) • Lateral load (MN)

  22. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Pile loads (ULS) for the tower piles • 1500mm piles 18-32MN in compression, average 24-26MN • 0-3MN in tension • 1800mm piles 30-51MN in compression, average 38-44MN • 0-5MN in tension • 2200mm piles 37-90MN in compression, average 50-60MN • 0-18.6MN in tension • Pile P11 (Ø2200mm) with ULS load of 90MN in compression • Pile P14 (Ø2200mm) with ULS load of 18.6MN in tension

  23. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Pile loads (ULS) for the tower piles

  24. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Major technical challenges of the project • Tower piles with very high compression and tension loads - ULS pile loads • up to 90MN (compression) and 18.6MN (tension) per pile • Requirements for elimination of structural concrete cracking under tension loads • → Minimum characteristic concrete principal tensile strength (f’ct) • shall be 0.4√ fc’ • Pile installation within tolerances is imperative • Installation of plunged columns in tension piles • Pile cut off levels located 9m and 14m below working platform

  25. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Options for compression loads • Driven piles • Not suitable for the intensity of loading • Raft foundation (stiffened raft/slab or piled raft) • Considered by McConnell Consulting for basement/podium foundations • CFA piles • Used for podium foundations • Bored piles socketed into rock • Used for tower foundations

  26. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Options for tensile loads • Driven piles • Not suitable for the magnitude of loading, joints etc • Raft foundation (stiffened raft/slab or piled raft) • Not suitable for uplift in excess of dead weight • CFA piles • Problems with full length reinforcement • Bored piles socketed into rock • Used for tower foundations

  27. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Pile Design - Piling works as D&C contract Piling Contractors first tender proposal Revised and optimized proposal

  28. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Why was the reduction of 3000mm to 2200mm piles important? • 3000mm piles with 86% more volume (influences drilling rates, cleaning • of drilling fluid, storage capacities, steel and concrete quantities) • 3000mm piles with 36% deeper rock sockets

  29. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast How can the tension capacity of bored piles be improved? → Use of high strength concrete (fc’ > 85MPa) for the pile shaft providing additional tensile capacity • Workability criteria • several 1500mm and 1800mm piles were installed and poured successfully with the 65MPa mix (no blockages) • slump of 260mm, spread 600mm • workability for 8-10 hours to ensure contingency • delivery and supply of concrete without delays • no concrete bleeding or segregation observed • concrete strength achieved

  30. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Use of high strength concrete • Plunged column installation • site trial with a test column in a 1500mm pile to verify minimum • plunged depth of 10m into concrete

  31. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Use of high strength concrete • Plunged column installation

  32. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Concrete Design Requirements • Design criteria • according to minimum characteristic concrete principal tensile • strength (f’ct) > 0.4√fc’ and maximum tension loads (ULS) of 19MN • for a pile diameter of 2200mm (cross section of 3.80m2) → f’ct > 5MPa • Previous experience suggested that the tensile strength of concrete is about 5-8% of the compressive strength → fc’ ~ 65-100MPa • Concrete supplier tested 6 samples from an earlier project where a 70MPa mix achieved 100-110MPa compressive strength after 56 days → f’ct > 6-7MPa • Preparation of a 85MPa concrete mix to target 100-110MPa

  33. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Trial with three mixes • Minimum compressive strength of 85MPa • Minimum tensile strength of 5MPa • Workability of 8-10 hours • All mixes designed not to absorb / release • water from / to environment • Proposed trial mixes for the 85MPa mix • Three different trial mixes: • S851FLL based on workability criteria of 65MPA mix • S851FLLFib with added synthetic fibres (extra tension capacity) • S851FLLretrial with reduced hydration stabilizing admixture

  34. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Concrete workability criteria • Testing if the mix is homogeneous

  35. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Concrete workability criteria trial mixes - S851FLL Fib

  36. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Concrete workability criteria trial mixes - spread test S851FLL Fib

  37. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Concrete workability criteria trial mixes

  38. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Indirect Tensile Strength Test AS1012.10-2000 (Splitting Test) Taking a sample on site Put sample into test jig under hydraulic cylinder

  39. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Indirect Tensile Strength Test AS1012.10-2000 (Splitting Test) Different test set up Sample in test frame

  40. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Indirect Tensile Strength Test AS1012.10-2000 (Splitting Test) Stress distribution Cracked samples inside a sample showing typical failure mode

  41. 5 MPa Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Results

  42. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Site Trial • Test workability on site on a compression pile (1500mm) • 1500mm pile with a plunged column test installation

  43. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Site Trial • Excellent workability criteria for SF851FLL • Plunged column installation up to 10m into concrete (suspend column)

  44. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Site Trial • Workability criteria for SF851FLL Fib critical • Fibres might get caught on reinforcement cage • or plunged column shear studs

  45. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Site Trial - Summary: • Successful site trial • Risk that fibers get caught on reinforcement cage or plunged columns considered as too high, fibres reduced workability of the mix • Workability criteria of SF851FLL excellent • Early tensile strength of SF851FLL > 5MPa after 7 days • Early compression strength of SF851FLL > 80MPa after 7 days…

  46. 1500mm 1800mm 2200mm Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Overview of all piles with high strength concrete (fc’>85MPa) column f’c>85MPa

  47. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Tensile Test Results • 76 tensile strength results were taken for the whole project: • 3 tensile and 3 compressive samples for every 50m3 • of 85MPa concrete • 2 early strength tests after 2 days: f’ct = 5.2 – 5.4MPa • 23 early strength tests after 7 days: f’ct = 4.3 – 6.4MPa • 8 strength tests after 28 days: f’ct = 6.6 – 7.5MPa • 43 strength tests after 56 days: f’ct = 6.6 – 8.5MPa

  48. test results after 28 days test results after 56 days test results after 7 days Minimum tensile strength requirement of 5MPa after 28 days Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Summary Tensile Strength Results

  49. Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Quality Control – Concrete Displacement Records theoretical volume actual volume

  50. 1500mm 1800mm 2200mm low strain cross hole Extreme Compression & Tension Loads for the Souls Tower on the Gold Coast Pile Layout Plan – Integrity Tests

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