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3
= 40
Hard, Weathered TUFF
> 40 N
= 20.0 MPa Mc
= 200 kPa Cu
= 20 kN/m n
3
Figure 2. Generalized Soil Profile and Geotechnical
Properties of soil layers for East Cooling Tower,
HRSG 1, HRSG 2 and HRSG 4
Table 1 Dimensions and depth of foundations of Power
Plant Facilities
Structure Length
(m)
Width
(m)
Df (m)
Cooling Towers 113.4 30.60 0.45
Heat Recycle Steam Generator 39.50 17.00 2.10
Combustion Turbines 35.00 17.00 1.35
Steam Turbines 40.00 20.00 2.85
Main Set-up Transformer 13.00 10.00 2.35
Auxiliary Transformer 13.10
8.70
10.00
8.00
2.35
1.05
Waste Neut. Tank D= 8.00 D= 8.00 1.00
Fire Water Storage Tank D=12.20 D=12.20 1.00
Demin. Water Storage Tank D= 9.15 D= 9.15 1.00
All of the facilities to be built within the Alia8a Power
Plant will have foundations resting on stiff gravelly clay
layers. The average allowable bearing capacity for the
shallow foundations of the facilities was calculated as
qall = 100 kPa.
Foundations of the facilities to be constructed will exert
soil pressures between 50 kPa and 127,5 kPa. The base
pressure transferred from the Fire/Filtered Water
Storage Tank to the soil is determined as 180 kPa.
In the facilities other than the Steam Turbine Generator
(STG) and Fire/Filtered Water Storage Tank, bearing
capacity problems are not expected.
Settlement analyses were carried out for the various
buildings and facilities in the Power Plant. Base
pressures, predicted total and differential settlements for
the facilities are summarized in Table 2.
Since the predicted total and differential settlements are
not tolerable, foundation of the structures were proposed
to rest on shallow foundations after the soil
improvement. Jet grout columns were selected mainly
for supporting the raft foundations and single footings of
the structures to transfer the base loads of 50 to 180 kPa
to denser strata, thus controlling settlements and
improving the compressibility characteristics of the soil.
Table 2 Predicted Settlements of Facilities Resting on
Shallow Foundations
Structure
Base
Pressure
(kPa)
Total
Settl.
(cm)
Diff.
Settl.
(cm)
Heat Recycle Steam Generator 1 100 22.4 11.5
Heat Recycle Steam Generator 2 100 26.2 13.6
Heat Recycle Steam Generator 3 100 21.4 11.2
Heat Recycle Steam Generator 4 100 19.9 10.4
Combustion Turbine 1 52.1 13.4 7.0
Combustion Turbine 2 52.1 15.9 8.6
Combustion Turbine 3 52.1 14.9 9.2
Combustion Turbine 4 52.1 10.8 5.7
Steam Turbine 1 127.5 28.2 14.4
Steam Turbine 2 127.5 28.9 14.6
Transformer 1 100 18.9 8.7
Transformer 2 100 19.9 8.9
Transformer 3 100 17.3 8.3
Transformer 4 100 18.3 8.2
Transformer 5 100 16.9 6.5
Transformer 6 100 16.8 6.6
Waste Neut. Tank 80 11.6 4.1
Fire/Filtered Water Storage Tank 180 20,6 7,9
Demin. Water Storage Tank (1) 110 16,2 6,7
Demin. Water Storage Tank (2) 110 16,1 6,7
West Cooling Tower 50 11,5 7,7
East Cooling Tower 50 12,8 8,5
Miscellaneous Footings
(2.5 m x 2.5 m)
100 8.5 3.5
As per the design, jet grout columns of 600 mm
diameter, 12 m effective length, with a service load of
450 kN, were selected. Distribution and spacing of jet
grout columns at the plant site are summarized in
Table 3.
Based on the design the total soil improvement work
consists of 78.000 m of jet grout columns of 600 mm
diameter.
TEST JET GROUT COLUMNS AND PROCESS
PARAMETERS
Thirteen 6 m long trial jet grout columns were installed
without pre-jetting in May 2000, using a water cement
ratio of 1:1. The top 2 to 3 m of each of the trial columns
were excavated and exposed so that the variation in
shape and diameter could be measured. Twelve 12 m
long test jet grout columns were than installed using the
optimum parameters derived from those trial columns.
All of these trial and test columns used a water cement
ratio of 1:1. Six of the test columns were cored to
measure their continuity and strength, while reinforcing
bars were installed in the other six and pullout tests were
performed to twice the design load (900 kN) in
accordance with ASTM D 3689.
Table 3. Jet Grout Column Distribution for Power Plant
Facilities
Jet Grout Columns
Structure
Foundation
Dimensions
(mxm)
Spacing
(mxm)
Number
Cooling Towers 113.4x30.60 2.5 x 2.5 996
Heat Rycyle Steam
Generator
39.50x17.0 2.0x2.0 1364
Combustion Turbines 3.50x17.0 2.5x2.5 996
Steam Turbines 40.0x20.0 1.8x1.8 1269
Main-Auxiliary
Transformers
13.00x10.00 2.0x2.0 414
Demin. Water Storage
Tank
D= 9.15 2.0x2.0 90
Electric Buildings 11.2x20.40 2.0x2.0 119
Switchyard -- 2.0x2.0 809
Water Treatment Plant 53x24 2.5x2.5 396
RMS Facility -- 2.0x2.0 45
Steel bars of 32 mm diameter were grouted into the
center core hole of the column for the column length.
Maximum and residual displacements of trial jet grout
columns are presented in Table 4.
Table 4. Results of Pull-out Tests Performed on Trial Jet
Grout Columns
Displacement
Jet Grout
No.
Test Load
(kN)
Max.
(mm)
Res.
(mm)
Trial 1 900 1.82 0.70
Trial 2 900 2.86 0.60
Trial 3 900 3.29 0.53
Trial 4 900 3.23 0.77
Trial 5 900 2.66 0.36
Trial 6 900 3.97 0.36
The majority of the test columns were excavated and
exposed to 3 to 4 m depth, while two were excavated to
around 7 m depth. The conclusions reached from the
test columns were that the pullout and strength capacity
were more than adequate while the diameter did not
generally reach the required 60 cm or minimum of
55 cm.
A further seventeen 12 m long trial jet grout columns
were installed with pre-jetting in July 2000, six using a
water cement ratio of 1:1, while the remaining 11 used a
water cement ratio of 1.25:1. Again, the diameters of the
excavated and exposed columns did not generally reach
the required average of 60 cm nor minimum of 55 cm.
An additional ten 6 m long trial jet grout columns were
then installed in pairs at 5 locations throughout the site in
late July 2000, using higher water and grout pressures.
All of these columns satisfied the diameter requirements.
The parameters listed in Table 5 were selected based
on the results of these trial jet grout columns for the
production jet grout columns.
All of the trial jet grout columns used SoilMec mixing and
pumping equipment and Casagrande drilling equipment
with 90 mm diameter rods and monitor with 2 nozzles
each 1.8 mm diameter and a drill bit diameter of about
120 mm.
Table 5. Process parameters
Jet Grout Column Diameter mm 600
Injection Pressure MPa 55
Number of Nozzles no 2
Nozzle Diameter mm 1.8
Rotation Speed of Rods rpm 20
Lifting Speed of Rods mm/min 350
Cement Consumption kg/m
3
630 710
Water / Cement Ratio w / c 1 : 1
Cement Type - OPC 42.5
Jet grouting is an eroding process, and therefore both
displacement as well as relaxation of the soil may occur
during grouting. Single fluid system combined with pre-
cutting has been used for the stiff cohesive soil layers to
ensure that a jet grout column of 600 mm or larger
average diameter is achieved.
QUALITY CONTROL TEST ON PRODUCTION JET
GROUT COLUMNS
As part of a comprehensive quality control program
pursued in the project, a number of quality control tests
were carried out during the production of jet grout
columns.
Coring and Strength Testing
Coring was performed one in every 50 production jet
grout columns, three samples from each cored column
were selected for strength tests 21 days after
installation. Each core was drilled about 10 cm off
center. Core drilling was performed using double-tube,
ball bearing swivel type core barrels. Each core run was
3 m in length. Unconfined compression tests were
performed on the core samples taken from the jet grout
columns, in accordance wirh ASTM C42. Unconfined
compressive strength values of qu= 3.6 MPa to 20.4
MPa were observed, with an average of 6.8 MPa
(Table 6).
Table 6. The results of uniaxial compression tests
carried out on samples taken from jet grout columns.
Area
Coring
(no)
Uniaxial
Test
(no)
Mean
qu
(MPa)
Power Block 1 38 114 6.7
Power Block 2 25 75 6.8
Cooling Tower 1 3 9 7.3
Cooling Tower 2 3 9 6.2
Switchyard 7 21 6.4
Water Treatment
Plant
3 9 8.5
Total : 79 237 6.8
Visual Inspection
A series of confirmatory jet grout columns were installed
close to production column area. During the execution of
works a total twenty nine 600 mm diameter, 7 m long
confirmatory jet grout columns were installed in each of
the 5 areas of the plant. Figure 3 shows the exhumation
of the jet grouting column for visual inspection.
All the test columns were excavated down to 3.5 m from
the working platform level. The columns were inspected
and the diameters of the column were measured at
every 500 mm. The followings are encountered :
The diameter of column varies between 600mm to
850 mm.
The average diameter at the top 3.5 m of the
column is greater than 650 mm diameter.
A slight reduction in the diameter at around ground
water level was observed.
Figure 3 Visual Inspection of Confirmatory Jet Grout
Columns
Integrity Testing
Integrity tests were performed in every 20 production jet
grout columns to assess the length and the integrity of
the columns. PDI pile integrity tester was used for this
purpose (Figure 4).
However, in the interpretation of the integrity test results,
it was observed that there is a difficulty in receiving clear
toe reflections since the modulus of elasticity of a jet
grout columns is very close to that of the soil layers
(Figure 5).
Figure 4. Execution of integrity test on a jet grout column
Figure 5. PIT Velocity Signal and Shaft Impedance
Profile for the tested Jet Grout Column
CONCLUSIONS
One of the largest jet grouting applications in Turkey is
described and discussed in this paper. The following
conclusions can be drawn from the results if this case
study:
1. 78.000 m jet grouting installation was completed
within a period of six months with close cooperation
among the general contractor, designer and jet
grouting contractor.
2. Pre-production test grout column installation assisst
in evaluating the effectiveness of the equipment to be
used and selection of the appropriate and optimum
injection parameters.
3. A comprehensive quality control and verification
testing program were incorporated in the project. The
properly planned and executed quality control
program resulted in early identification of potential
problems and allowed the contractor to make
necessary adjustment and/or modifications to solve
these problems.
4. The unconfined compressive strength of the jet
grouted soil ranged from 3.6 to 20.4 Mpa. The test
results exceeded the minimum specified strength of
3.2 Mpa. The results of strength tests reveal that the
measured unconfined compressive strength of jet
grouted soils are in conformity with the values
obtained in similar soil conditions.
5. Based on the trial test results performed at site, an
additional step was added to the basic procedure to
ensure that jet grout column of 600 mm or greater
diameter is achieved. Prior to jet grouting sequence,
a pre-jetting sequence was incorporated where high
pressure water is jetted through the nozzles, with
rotation and lifting in a similar manner to that used
during jet grouting.
6. The quantity of cement per cubic meter of treated
ground in stiff clay varies between 630-710 kg/m
3
.
REFERENCES
Saglamer, A., (2000). Geotechnical Report on Izmir
Alia8a Combined Cycle Power Plant. Faculty of Civ.
Eng., Geotechnical Engineering Department, Istanbul
Technical University.
Saglamer, A., Duzceer, R., Gokalp, A., Yilmaz, E.
(2001). Recent Applications of Jet Grouting for Soil
Improvement in Turkey Proc. 15
th
International
Conference on Soil Mechanics and Geotechnical
Engineering, ISSMGE Istanbul, vol. 3, 1839-1842.