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By Federico Pagliacci

Continuous Flight Auger (CFA) technique represents an important technological advance in the construction of piles in soft soils. The possibility of excavation under the water table with no need for drilling fluids, along with high productivity, have resulted in this technique?s becoming widespread in many countries. However, CFA technology has limitations because of its difficulty in penetrating hard layers and cross strata with cobbles and boulders. In these situations, pile verticality may be an additional problem. The Cased Augered Pile (CAP) technique consists of penetrating the soil with an auger housed in a casing. Two independent rotary heads sliding along the rig mast operate the auger and the casing. By adjusting the height of the casing shoe and auger bit according to soil type, it is possible to drill piles in very severe conditions - in the presence of cobbles and boulders - and to socket the pile into the rock. The use of a steel casing enables improved pile verticality. Therefore, the CAP technique is also used to construct secant piles to be used as diaphragm walls. The limitations of this technology are the depth, usually no more than 27 m (88 feet), and the size of the rig that supports the drilling tool, no less than 70 t (77 short tons) in working conditions. This paper illustrates CAP technology, the drilling system, and the characteristics of concrete and steel reinforcement and offers a case study of the Palermo-Carini second railway line, which used CAP to construct the new 30 km (18.6 mi) railway line, 20 km (12.4 mi) of which passes through the very congested downtown area of Palermo. More than 300,000 m (186.4 mi) of piles have been drilled in dense calcarenite formations with unconfined compressive strength of 15-25 MPa (2,200-3,600 lb/inch2), soft clay, and silt formations.

By Michael Oakland

This paper will discuss the design analysis of sheet pile cofferdams for static and dynamic blast loads. Following construction of the new Willis Avenue Bridge across the East River between Brooklyn and Manhattan, in-river piers No. 9 and No. 10 from the former bridge were demolished, partially by explosive charges. The blast at Pier 10 was conducted first and though the demolition charge was relatively small, it gave confidence that the sheeting could be designed to resist the blast load. This paper primarily summarizes our analysis and performance of a sheet pile cofferdam at Pier 9 used to withstand the larger blast loads, contain the blast debris, and allow excavation of the pier below the existing river bed mudline. The program NLFlex was used to predict stresses and deformations of the cofferdams under dynamic blast loads, using simplified equations to estimate the underwater blast pressures. Specifically, the analysis focused on the stresses in the struts, waler beam, sheet pile interlocks and connection of the sheeting to the waler beam. Design included allowing plastic deformations and limited rupture of the sheet pile interlocks under the blast loading. Comparisons are made between stresses assessed by the dynamic finite element modeling and empirical relationships used within the industry. The performance of the system after the actual blast is discussed as well as details of the performance of welded vs. bolted connections within the system.

By Donald T. Robertson

This paper presents case histories of driven concrete pile damage detected with dynamic testing methods utilizing strain gages and accelerometers embedded in the pile at the prestressing yard during pile construction. Data from the embedded instrumentation is compared with data taken with external bolt on instrumentation and other test methods such as low strain testing on the same pile. In the most severe cases, the piles were extracted revealing and corroborating the embedded data collector results.

By C. Vipulanandan

Installation procedure and the quality of the material used in the construction have significant effects on the behavior of the Auger Cast in Place (ACIP) piles. In this study, Installation and curing of a 760 mm (30 in.) diameter and 12 m (39 ft) long ACIP pile with a design capacity of 1140 kN (128 tons) in hard clay was investigated. Construction quality was monitored using the automated monitoring system where the volume of grout pumped and the pressures were monitored with depth. The curing of the pile was monitored using axial vibrating wire strain gages at four levels and lateral vibrating wire strain gages at two levels. The residual strain and temperature profile in the curing pile was monitored over a period of week to determine the appropriate time for load testing the pile. Axial behavior of Auger Cast in Place (ACIP) Piles in hard clay was studied using full scale load test on an instrumented pile. The load-settlement and load transfer relationships of the pile was investigated based on the load test results. Development of skin friction in the load test pile and the reaction pile was also investigated.

By Brendan Demich, Brendan Macdonald, Timothy J. Orr, Jason Navoyski, Jennica L. Bellanca, William J. Helfrich

Recent advances in computing, rendering, and display technologies have generated increased accessibility for virtual reality (VR). VR allows the creation of dynamic, high-fidelity environments to simulate dangerous situations, test conditions, and visualize concepts. Consequently, numerous products have been developed, but many of these are limited in scope. Therefore, the National Institute for Occupational Safety and Health researchers developed a VR framework, called VR Mine, to rapidly create an underground mine for human data collection, simulation, visualization, and training. This paper describes the features of VR Mine using self-escape and proximity detection as case studies. Features include mine generation, simulated networks, proximity detection systems, and the integration and visualization of real-time ventilation models.

By Miguel Reyes, Bruce Whisner, Joseph Bickson, Lincan Yan, David Yantek, Justin Srednicki, Nicholas Damiano, Eric Bauer

Built-in-place (BIP) refuge alternatives (RAs) are designed to provide a secure space for miners who cannot escape during a mine emergency. Heat and humidity buildup within RAs may expose miners to physiological hazards such as heat stress. To minimize the risk of heat stress, Title 30 Code of Federal Regulations (CFR), or 30 CFR, mandates a maximum allowable apparent temperature (AT) for an occupied RA of 35 °C (95 °F). The National Institute for Occupational Safety and Health (NIOSH) has conducted extensive research on the thermal environment of occupied RAs intended for use in underground coal mines. NIOSH research has demonstrated that a fully occupied BIP RA can exceed the AT limit by more than 5.6 °C (10 °F) in mines with elevated mine strata and air temperatures. In this circumstance, an RA cooling system could provide a solution. This paper provides an overview of test methodology and findings as well as guidance on improving the performance of a cryogenic air system prototype by optimizing the flow rate, increasing the tank storage capacity, and improving the efficiency of the heat exchanger of the cryogenic system. This may enable BIP RAs to meet the 35 °C (95 °F) AT limit in mines with elevated temperatures. The information in this paper is useful for RA manufacturers and mines that may choose to implement a cryogenic air system as a heat mitigation strategy.

By O. T. Rämö, E. Suikkanen

Episyenites are sub-solidus, quartz-depleted alkali-feldspar-rich rocks. They form veins and lenticular bodies in granitoid rocks and migmatites in a late- to post-orogenic or anorogenic setting. Leaching of quartz is usually a response to a flux of weakly saline hydrothermal solution in circulation cells above cooling intrusions, where sufficient fluid-rock ratios and thermal gradients are achieved. Fluid Si-undersaturation is achieved by rapid cooling within the field of retrograde Si solubility or by temperature and pressure increase outside retrograde conditions. Some quartz may also be consumed in metasomatic reactions and in response to pressure fluctuation in sealed episyenite bodies. The small size and overall rarity of episyenites imply that conditions for episyenite formation are not commonly encountered in the crust. In addition to quartz depletion, episyenites record complex histories of metasomatic alteration and hydrothermal mineral growth. Nearly all episyenites have undergone Na-metasomatism, which may have led to the formation of nearly monomineralic albitite, and which is occasionally followed by late K-metasomatism, phyllic alteration, and argillization. Depending on the effectiveness of later compaction, recrystallization and vug-filling episyenites may preserve the macroscopic porosity formed by quartz dissolution and brittle deformation. Vuggy episyenites can act as significant sinks for metals carried by crustal fluids and host many significant U, Sn, and Au deposits worldwide. Rare earth-critical syenitic fenites around alkaline intrusions share mineralogical and genetic traits with episyenites.

By Thomas A. Gray, Lynn M. Crayne, Michael A. Trevits, Phil Glogowski

Mine seals can be remotely constructed in underground coal mines, through vertical boreholes, when direct access to a fire is impossible or considered to be too dangerous. This method has great merit because boreholes can be drilled to specific mine areas and seals can be positioned close to a fire zone. The technology however, can be largely ineffective if the constructed seals do not provide effective barriers to airflow or cannot be used to impound water and other inert materials. Unfortunately, no viable alternatives exist to sealing the entire mine at the ground surface. Full-scale remote mine seal construction research is being conducted at the National Institute for Occupational Safety and Health’s (NIOSH) Lake Lynn Laboratory (LLL). Under this effort, Howard Concrete Pumping Company and GAI Consultants, Inc. have joined forces to evaluate a potentially significant improvement to the current state-of-the-art. This paper will cover development of novel technology for remote mine seal construction, evaluation of the materials used, construction practice, and follow-up testing.

By Mustapha A. Raji, Alafara A. Baba, Christianah O. Adeyemi, Aishat Y. Abdulkareem, Rafiu B. Bale, Malay K. Ghosh

The increasing demand for pure aluminum and aluminum compounds of industrial quality from kaolinite ore cannot be overemphasized. Nigeria is one of the African countries endowed with abundant solid mineral resources that have not been sufficiently exploited to assist its indigenous industries. A wide array of applications of pure aluminum and its compounds are available, such as paper filling, refractories, adsorbent, catalysis, and paint additives. In this study, the upgrading of a Nigerian biotite-rich kaolinite ore by a hydrometallurgical route was investigated in oxalic acid media. During leaching studies, the effects of parameters including reaction temperature, lixiviant concentration and particle size on the extent of ore dissolution were examined. At optimal conditions (1.0 mol/L C2H2O4, 75 °C), 92.0% of the initial 10 g/L ore was reacted within 120 min. The dissolution curves from the shrinking core model were analyzed and found to conform to the assumption of surface diffusion reaction, and the calculated activation energy of 33.2 kJ/mol supported the proposed model. The unreacted product (~8.0%) analyzed by XRD was found to contain siliceous impurities and could serve as a valuable by-product for certain industries.

By Miguel Reyes, Bruce Whisner, Joseph Bickson, Lincan Yan, David Yantek, Justin Srednicki, Nicholas Damiano, Eric Bauer

Built-in-place (BIP) refuge alternatives (RAs) are designed to provide a secure space for miners who cannot escape during a mine emergency. Heat and humidity buildup within RAs may expose miners to physiological hazards such as heat stress. To minimize the risk of heat stress, Title 30 Code of Federal Regulations (CFR), or 30 CFR, mandates a maximum allowable apparent temperature (AT) for an occupied RA of 35 °C (95 °F) (MSHA 2008 [1]). The National Institute for Occupational Safety and Health (NIOSH) has conducted extensive research on the thermal environment of occupied RAs intended for use in underground coal mines. NIOSH research has demonstrated that a fully occupied BIP RA can exceed the AT limit by > 5.6 °C (10 °F) in mines with elevated mine strata and air temperatures (Bissert et al. 2017 [2]). In this circumstance, an RA cooling system could provide a solution. This paper provides an overview of test methodology and findings as well as guidance on improving the performance of a cryogenic air system prototype by optimizing the flow rate, increasing the tank storage capacity, and improving the efficiency of the heat exchanger of the cryogenic system. This may enable BIP RAs to meet the 35 °C (95 °F) AT limit in mines with elevated temperatures. The information in this paper is useful for RA manufacturers and mines that may choose to implement a cryogenic air system as a heat mitigation strategy

By António Fiúza, Anthony Danko, Patrícia Leitão, Aurora Futuro, Cristina Vila, Lurdes Dinis

The average global recovery rates for processing scheelite ores by physical methods are normally in the range 50 to 70%, and it is problematic to attain a minimum grade of 60% WO3 in the concentrates without penalizing further this yield. Direct hydrometallurgical processing of low-grade concentrates or medium- to high-grade ores may become an interesting global economic alternative as it allows increasing the recovery rate, avoiding major penalizations due to the grade of the concentrate and increasing the added value of the final product. Leaching of scheelite by sodium carbonate presents several advantages such as its selectivity regarding the dissolution of troubling metals like iron and aluminium, allowing for a simple and flexible process diagram. However, it has the disadvantage that it is performed at high temperature and pressure with a high consumption of reagents. The feasibility of leaching is appraised by the extraction yield and selectivity, but also by the operating cost. Considering these aspects, a relevant objective of the research was to transform alkaline pressure leaching into a feasible processing alternative directly applicable to both medium- and high-grade ores and simultaneously to low- and high-grade concentrates produced by physical methods. The research used ore samples and low-grade concentrates from a typical skarn orebody as well as high-grade concentrates from a chalcopyrite-scheelite orebody. Different operating conditions were tested. Temperature, pressure and reagent concentration showed to be fundamental, but not exclusive, in determining the leaching behaviour. The operating conditions are milder than the ones generally proposed in the literature or currently in use in industry, but with higher carbonate consumptions. The research was oriented towards potential industrial implementation allowing for the application of optimization methods and straight scale-up to pilot-plan design and project.

By Sailesh S. Author

The current design method for soil-cement (SC) columns improved soft clayey ground under the highway embankments assumes a slip circle failure surface shearing through the columns and the soils using a weighted average shear strength. However, the results from the laboratory centrifuge model test and numerical analysis indicate that in many cases, the SC columns fail by bending. Some researchers have proposed methods for estimating the maximum embankment loading for bending failure of SC columns, but those methods have limitations in correctly considering the internal shear stresses or not applicable for the group SC column improvement. Numerous model embankments on SC columns have been simulated by three-dimensional (3D) finite element analysis (FEA) and the mechanism of bending failure and the magnitude of the bending moment in the SC columns under embankment load has been investigated. Based on the simulated results, the design method for the estimation of the bending failure of floating SC columns has been proposed. The predicted results from the proposed method agreed with the existing field condition of one embankment in Saga, Japan reported in the literature in terms of the stability of columns. Hence the proposed method can be used for the design of floating SC columns in the soft ground.

By Daniel Ruffing, Charlie Krug

In recent years, the chain-style trencher has been proven a valuable tool for installing vertical walls on challenging sites where conventional methods may be less desirable. Like many tools, trenchers are most effective when used with the right application. Trenchers are commonly used for applications that could also be completed with conventional slurry trenching; low-permeability cutoff walls, collection trenches and permeable reactive barriers (PRBs). Drawing from a wealth of experience with conventional slurry trenching and the trencher, this paper compares and contrasts the technical considerations, treatability, installation, performance, and lessons learned for recent projects.

By Stefan Schwank, Alexander Blatt, Franz-Werner Gerressen

Diaphragm wall technique is usually used to install diaphragm walls, which are known as underground structural elements commonly used for retention systems and permanent foundation elements as well as deep groundwater barriers, named Cut-Off-Walls (COW). In this exploration project, the diaphragm wall equipment was used in the 2019 summer season to perform the first part of an exploration and bulk sampling program for a potential mine on the Star Kimberlite. Beside the idea of using the diaphragm wall technique as bulk sampling equipment, the sampling program required the adaption of equipment and tools for a depth capability never reached before by a trench cutter in any commercial application worldwide. The paper will explain the development of the sampling program as well as the challenges occurred with the local geology and the specific demands of the exploration and sampling program. It will also provide an overview of the lessons learned during the 2019 season and will give an outlook to the approaches of optimization for the second phase which will be carried out in 2020.

By Eric S. Lindquist, Charles A. Luxford

The State of Texas recently adopted a master plan to expand the existing Capitol Complex in Austin. Phase 1 of this expansion will add two new State office buildings and five levels of underground parking to the existing Complex. Additionally, a landscaped pedestrian mall will be built atop a portion of the underground parking to enhance the area as a cultural destination. Capitol Complex website: https://www.tfc-ccp.org/ Brierley Associates was selected to provide detailed design of the entire Phase 1 earth retention system for an approximately 40-65 ft (12-20 m) deep, 500,000+ yd3 (380,000+ m3) excavation through overburden soils and limestone bedrock. To facilitate overall project coordination, all design packages were required to develop Revit models, including the retention system package. With the project located in an urban setting, this 3D model also facilitated coordination of the retention system with adjacent major structures and utilities. The retention system is a combination of soil nails, soldier piling with tiebacks and rock anchors with a shotcrete facing as a substrate for the below-grade blindside waterproofing system. Due to the substantial scope of excavation, a significant number of utilities had to be routed on a temporary span over the excavation. Brierley Associates designed this utility support structure, which required extensive coordination with the excavation support and existing utilities located directly underneath the structure’s foundations. Preconstruction geotechnical work identified a fault zone that might be encountered within the excavation; however, the fault feature was found to have a more adverse location and orientation than originally anticipated. This observation required that a portion of the temporary anchors be converted to higher-capacity, corrosion-protected permanent anchors.

By Armin W. Stuedlein, Steven R. Saye

The differences between calculated axial pile capacity and the capacity realized during and following installation has long presented a significant concern for foundation engineers and contractors. Such differences have increased in prevalence with the increased use of larger diameter steel pipe piles and the significant increase in design-build contracting. The writers present concepts to close the gap between calculated axial pile capacity and the capacity realized during and following installation of driven pile foundations, including: (1) pile set-up in plastic soils, (2) limitation of re-driving of piles after setup which serves to reduce pile capacity, (3) the use of a vibratory hammer to install piles in cohesive soils disturbs the supporting soils and reduces the pile side resistance capacity significantly, and (4) long pile installation times for open-ended piles can damage the pile side resistance. Examples are presented from practice to illustrate these concepts and to guide pile installation planning to recognize the installation impacts and either consider alternate installation approaches or to properly consider the installation impacts during design.

By Greg Plutko

Laboratory testing has shown that the Marsh Funnel test can be significantly impacted by long-chain polymer entanglement. In general, shorter hydration time leads to more chain entanglement which in-turn, leads to higher marsh funnel values that values seen for longer mixing. This trend makes it very difficult to predict funnel-viscosity on successive days. Data is presented which helps to explain this chain interaction effect on Marsh Funnel data and how it differs from traditional Fann viscosity. The data suggest that this long-chain polymer entanglement occurs more in samples with less hydration time and decreases as hydration time increases. There is also suggestion that higher polymer concentrations have a greater drop-off in marsh funnel viscosity for a given aging length than do lower solids slurries. Fann rheology was shown to be much less impacted by the hydration time of the PHPA polymers than was Marsh Funnel viscosity. This suggests that the Marsh Funnel viscosity is impacted by some aspect of the slurry that does not affect Fann rheology as strongly. It is known from literature that longer-chained polymers have more potential to entangle and our data support the theory that the Marsh funnel viscosity is greatly impacted by this polymer-chain ‘roping’ entanglement.

By Gisele R. Passalacqua, Aly Mohammad, Joanna Smith

The $13 billion John F. Kennedy (JFK) airport construction redevelopment program includes new terminals and buildings that are supported on piles to meet the airport expansion demand due to increased travel. This paper presents a case history for JFK airport with main focus on construction activities and lessons learned. Challenges include limited head room, presence of underground utilities, and hard driving. Video inspection of pile proved very beneficial. In general, soil conditions at JFK Airport consists of sandy fill followed by a 5-foot thick organic soft layer. Below the organic layer, glacial sands occasionally mixed with gravel were encountered for great depth with increases in density with depth. The tapertube pile is an ideal choice for foundations with high capacity achieved through skin friction along the taper section. The piles are easy to splice to accommodate low head room. Pile Driving Analyzers (PDA), and Static Compression Load Tests were performed. The results of these tests are presented in this paper to illustrate the high pile capacity achieved. More detailed discussion and analysis of the test results will be presented in another paper related to the same project. Lessons learned from this project are shared to help the engineering community with future design and construction of similar projects.

By Robert H. Peters

Are the safety rules in your work place effective? Do supervisors enforce them as they should? Do supervisors abide by these rules? Safety rules are an important aspect of many company safety programs, particularly if employees must work in an intrinsically hazardous environment such as a coal mine. However, for various reasons, supervisors sometimes fail to enforce safety rules (Arvey & Jones, 1985; Hartshorn, 1998). This paper presents some findings obtained from interviews with coal miners about why supervisors sometimes fail to enforce an important mine safety rule. It also contains a few suggestions addressing what could be done to help supervisors perform this job function more effectively.

By Waddah Akili

This paper describes the steps taken in planning, developing, and executing a case study/ case history course in geotechnical/ foundation engineering at an international university. The paper sheds light on: how a “workable” format for the course was arrived at; the organization of the course; and the results of evaluating the effectiveness of this approach versus traditional lecturing. Problems and challenges that could arise when offering the course for the first time are also addressed. Embedded in this experience and its related protocols are: the emphases on engineering design and the practice, teamwork and leadership development, organizational management, and oral and written communication skills. The paper concludes by confirming that discussions, through an open forum, are judged to be superior to traditional lectures in improving critical thinking, cultivating desirable personal attributes, and acquiring problem-solving skills.