Complex Geotechnical Aspects of

Mega Projects and Their Effective

Management Changi WRP Project
Singapore Experience
Dr. Suresh Parashar, Ph.D., P.E., MASCE
Senior Technologist, CH2MHILL International, UAE

&

Edward Sloan, CCM, PMP

Senior Construction Manager, CH2MHILL International, USA

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Scope of Presentation

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Introduction to DTSS & CWRP

Geotechnical Aspects of CWRP

Ground Water Cut-off Wall

Deep Excavation and Slope Stability

Supplementary Site Investigation

Pumping Station Deep Shafts

Deep Foundations

Summary & Lessons Learnt

Introduction to DTSS & CWRP

DEEP TUNNEL

Phase 1 capacity : 176 MGD (800,000 m3/day)

Ultimate capacity : 528 MGD (2,400,000

m3/day)

Construction period: 2001 to 2008

Estimated cost : SGD$2.2 Billion (~US$ 1.5 Billion)

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CHANGI WATER RECLAMATION PLANT

Project Statistics
Planned Project Duration: Apr 2001 - Dec
2007, 81 months.
Peak construction expenditure (in 2005)
S$45 Million/month (~US$ 35 Million).

Construction team 400,000 man-months,

peak staff of 6000 - 7000.

Workers living on site - 3000.

Total value of contracts - S$ 2.2 billion.

13 Construction packages and 8 equipment

procurement contracts.

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Project Statistics

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Geotechnical Aspects of CWRP

Ground Water Cut-off Wall
Deep Open Excavation & slope
Stability
Supplementary Site Investigation
CBP Retaining Wall

Ground Improvement (Jet

Grouting)
Temporary Excn. Support - Sheet
Piles, H Piles / Timber Lagging, DWall, Soil Nails, Walers & Struts
Pumping Station Deep Shafts
Diaphragm Walls
Interconnecting Tunnels (NATM)
Bored Piles Design, Construction
& Pile Load Tests
Geotechnical Instrumentation &
Monitoring
Backfilling

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Ground Water Cut-off Wall

2700 m long perimeter cement

bentonite ground water cut-off

wall (Est. Area = 73,400 m2) to
keep the ground water away
from entering the open
excavation during construction.

Total Length

2700 m

Thickness

600 mm

Depth

21 30 m BGL
(RL 105)

Primary Panels

6 m to 7.7 m long
(3 Bites of Grab)

Secondary
Panels

1.9 m to 2.2 m
(1 Bite of Grab)

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Ground Water Cut-off Wall

Design and Construction Challenges
The specialist contractor, based on his previous experience, proposed a cement

bentonite slurry cut-off wall consisting of 200 kg PBFC Cement, 30 kg GTC 4

Bentonite and 925 kg of Water in one cubic meter of slurry.
In the CB method, self-hardening slurry typically contains (by wt.) - 4 to 7%
Bentonite, 8 to 25 % Cement and 65 to 88 % Water.
The CB Proportions (by wt.) of Contractors Proposal: 2.6 % Bentonite, 17.3 %
Cement and 80.1 % Water.
Design mix that has too little bentonite leads to cement setting out and excessive
water bleeding.
Design Mix will be UNSTABLE & thus NOT SUITABLE (GTC4#1 21% Bleed).

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Design and Construction Challenges (Cont.)

Finalized Design Mix
Material
Non-Marine Clay
Area

Marine Clay
Area

Cement

200 kg

155 kg

Bentonite

50 kg

55 kg

Water

917 kg

929 kg

4.5%

4.5%

36 sec

34 sec

Bleed (2 Hr)
Viscosity

Lessons Learnt:
Verify the relevance of previous
experiences (applicability & performance)
Have a reasonable questioning
attitude, seek details to avoid surprises
Be part of solution & follow-up
Team work approach seek win
win solutions
Manage stakeholders expectations

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 Design and Construction Challenges (Cont.)

CB wall was excavated using Mechanical & Hydraulic Grabs. As excavation
progresses, the CB slurry becomes increasingly difficult to work and slows down
the productivity.
Contractor proposed to use the replacement method - to excavate the trench
under bentonite slurry, to be subsequently displaced by cement bentonite slurry.
Mock-up demonstration tests were carried out in a Perspex tank, showed
promising results. A cut-off wall primary panel was constructed using this
technique and tests were conducted to verify performance as hydraulic barrier.
Result - The constructed panel could not hold water in the cored space at the
middle of the panel.
Observation - Inadequate density difference between the bentonite slurry in the
trench and the CB slurry for replacement method produced unsatisfactory cut-off
wall.
In a recent project, replacement method has been used satisfactorily where CB
wall is constructed using Hydromills. At the end of excavation, the bentonite slurry
in trench is replaced by fresh bentonite slurry just prior to its replacement with
Cement Bentonite slurry using special delivery tremie pipe.
Lesson Learnt Construction method and equipment used have to be
compatible as they govern the final performance . Verify the expected
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performance to avoid unexpected surprises.

Deep Open Excavation and Slope Stability

Open Excavation up to 22 m Deep

(Mass excavation of approximately 4.5

Million m3).

Slopes designed with adequate safety

factors based on subsurface conditions
identified at the design stage.
During additional investigation along
cut-off wall perimeter, significantly thick
deposits of soft marine clay encountered
along the eastern & northern sections.
Based on revised sub-surface profiles
& estimated shear strength of marine
clay, slopes were deemed to be
unstable (PLAXIS & FLAC Analysis).
Slope stabilization measures would be
required!!

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Deep Open Excavation and Slope Stability

The proposed slope stabilization 50m

wide Jet grouting at the center of slopes

Est. Cost : US$ 10 to 15 Million
Est. Project Delay: 6 months to 1 year
The Critical Questions:
What is the exact extent of the soft
marine clay and its thickness?
What is its in-situ shear strength?
How does it really impacts the
stability of slopes?
Where are most critical sections?
Put simply, Do we understand the
real problem and its actual extent?

Without understanding the real

problem, how could we find the
optimum fix for it?

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 To seek answers to critical issues:

Supplementary SI planned with following critical requirements & approach :

Ensure highest quality investigation possible, award the investigation work

based on quality rather than cost basis.

Cone Penetration Tests (CPTU) to determine the profile of marine clay along
the proposed cut-slopes as well as their estimated engineering properties.

Based on CPT profiles, identify the locations for boreholes.

The SI layout was continuously reviewed by the Engineers geotechnical staff

as the site investigation work progressed and adjusted accordingly, if
required.

Boreholes at close proximity at select locations to allow collection of an

adequate number of samples for laboratory testing.

Boreholes were drilled to different depths in the soft clay, with installation of a
rapid response piezometer near the bottom of each borehole to provide a
groundwater pressure profile through the soft clay. Each piezometer was
calibrated in an open deep well prior to installation in the borehole.

Field Vane Tests were carried out to determine the undisturbed and remolded
in-situ shear strength of soft soils.

The undisturbed samples were X-rayed in the tubes to determine the quality
of the samples and natural variation within the samples to guide test
specimen selection.

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 Deep Open Excavation and Slope

Stability (Cont.)

Supplementary SI critical requirements &

approach (Cont.): Lab Testing

The advanced laboratory testing by NTU

consisted of K0 Consolidated Undrained
Tri-axial Compression (CK0UC) tests, K0
Consolidated Undrained Tri-axial
Extension (CK0UE) tests, K0
Consolidated Undrained Direct Simple
Shear (CK0UDSS) tests and OneDimensional Consolidation tests.

In addition, some physical property tests

such as liquid limit, plastic limit and
specific gravity were also conducted.

Additional laboratory tests such as index

tests, grain size distribution, UU, CIU and
consolidation tests were carried out at
contractors laboratory. Samples at the
contractors laboratory were extruded in
the Engineers presence who selected
the samples for different tests.

Total Cost of SI = SG$ 184 K (US$115K)

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 Slope Stability (Cont.)

Critical slope sections were re-analyzed

using PLAXIS FEM Program &
PCSTABLE slope stability program.

Slopes had adequate safety factors.

Slope
Section

Est.
Factor of
Safety

Undrained
Analysis

Drained
Analysis

Remarks

PCSTABL
6

1.39

1.51

Northern
Slope

PLAXIS

1.45

1.53

Northern
Slope

PCSTABL
6

1.25

1.42

North-East
Corner

PLAXIS

1.26

1.42

North-East
Corner

PCSTABL
6

1.40

1.77

Eastern
Slopes

PLAXIS

1.44

1.83

Eastern
Slopes

II

III

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 Slope Stability (Cont.)

Contiguous Bored Pile Wall at Effluent Junction Chamber (12 m Cantilever

CBP Wall) had required ground improvement works using Jet Grouting based
on original designs
CB Wall reanalyzed without Jet-Grouting based on data from supplementary
SI and better quality MC properties.
Result - Jet Grouting Not required
Omitted Jet Grouting saving S$2.9M, after compensating contractor for
design work, test trials and loss of profit.

Potential Risks of Slope Instability & CB Cut-off wall interaction

The sub-soil conditions could still be worse than those discovered by site
investigation at some unknown location
Any slope failure could result in breach of cut-off wall.
This could result in flooding of deep excavation endangering lives of workers,
property damage & project delays

This risk would be unacceptable

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 Risk Monitoring Approach

Monitor the performance of cut-slopes, CB wall, plan contingency

measures in advance to be adopted if any slope section shows signs of
instability

Adjust the monitoring frequency depending on construction progress

and behavior of cut slopes

Final Results All slope sections and CB wall performed satisfactorily.

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Lessons Learnt

The quality of SI data is most critical. Its quality rather than quantity that
matters. The additional cost to ensure highest quality possible for SI
investigation pays huge dividends in reliable data & designs and minimized
project risks of cost overruns and schedule delays etc.

Designs are only as reliable as the design input irrespective of sophisticated

computer programs.

Understanding of actual extent of problems, design assumptions, correlations

for estimating soil properties etc needs to be critically reviewed and verified.

Comprehensive risk monitoring programs including contingency measures

need to be in place.

Teamwork approach, stakeholder management is critical.

Finally, use the language of Decision Makers while conveying the potential
risks, available options to manage them, associated costs and benefits while
seeking senior management / client endorsements.

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Pumping Station Deep Shafts

Influent Pumping Station Shafts 40 m
in diameter and up to 72 m deep shafts
built using circular diaphragm walls.
Coarse Screen Shaft (CSS) receives
raw / treated effluent from DTSS (T01) &
screen out larger particle, guides flows
into Influent Pumping Stations (IPS) that
pumps the flow into Influent or Bypass
pipelines.

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Pumping Station Deep Shafts (cont.)

The IPS shafts were designed to be constructed

by first installing 1.2 m thick circular diaphragm
walls. Inner RCC Ring Walls, 1.6 m thick, were
designed to carry all the loads from the base and
intermediate equipment levels, as well as lateral
ground loading following a top-down staged
construction sequence in 10 stages.
The diaphragm wall shafts were constructed
using Bauer BG50 crane-mounted hydromills.
The nature, availability and cost of this equipment
meant that only two sets would be available for
the IPS work.
A risk analysis identified that the construction of
these large, deep shafts not only lay on the
critical path, but had the potential for
significant cost and schedule overruns.
It became clear to the project team that other
measures would be necessary if the project
schedule was to be achieved.

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Pumping Station Deep Shafts (Cont.)

Alternative sequences, taking into account the level of intermediate

structural slabs and shaft wall penetrations were considered and analyzed
using the finite element method software, PLAXIS.

It was concluded that a reduced number of 8 stages would keep the

compressive loading due to hoop stress, as well as bending moments of
the panels to acceptable levels while providing considerable time
benefits and necessary comfort level to all stakeholders.

A comprehensive system of instrumentation was then developed to allow

verification of site performance with the theoretical analysis at all stages of
construction, and contingency plans were also developed to revert to the
more conservative excavation sequence should the need arise.

The performance monitoring of the diaphragm wall panels for actual behavior
during construction provided the tool for risk management and the necessary
comfort level to approve and adopt the revised excavation sequence up to
EL 64 (i.e. top 38 m of shafts). Below this depth, the original excavation
sequence with minor adjustments for the construction requirements was
adopted in the construction of IPS shafts at CWRP.

The IPS shafts were completed on time and Pumping Station Facility was
commissioned ahead of schedule.

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Lessons Learnt

An informal partnering arrangement

resulted in an open teamwork
approach to the works which
provided the framework for
alternative methods to be
successfully adopted for the benefit
of the project and all stakeholders.

Use of extensive instrumentation to

verify, confirm and validate
assumptions that had been made in
the theoretical analysis, and to
empower the site staff with the tools
to demonstrate the performance of
the shafts at all stages of
construction.

The final result was that the shafts

were safely constructed below
budget, allowing the Influent
Pumping Station to be
commissioned and operational 4
months ahead of schedule.

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Bored Piles Design, Construction & Load Testing

The CWRP project involves more than
3300 bored piles of diameters ranging
from 700 mm to 2200 mm.

Piles were designed with Full Length

Reinforcement. Estimated total length of
bored piles at CWRP = 160,000 m.
Pile
Dia.
mm

No.
of
Piles

No.
of
Pile
Tests

700

142

1300

Working Load
Comp
Tons

Tension
Tons

307

1010

10 +
3 (ULT)

1060

300

1500

140

1410

470

1800

335

2035

680

2000

1332

13

2510

700

2200

170

3040

700

Total

3129

31 +
3 (ULT)

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Bored Piles Design, Construction & Load

Testing

Ultimate Load Tests on instrumented piles

using Kentledge method (2) and Multi-stage
O-cell method (1) conducted from existing
surface with de-bonded casing and strain
gauges to obtain site specific design
parameters ahead of completion of
excavation due to critical schedule.
LOAD TRANSFER CURVES

500

1000

1500

2000

2500

3000

3500

105

ELEVATION, (mRL)

95

85

570
75

1135
1668
2178

65

2469
2715
2950
3192

55

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Bored Piles Design, Construction & Load Testing

Site Specific Design Correlations
Shaft Friction
Depth

SPT N

Measured
fs
- I Cycle

Measured fs
2nd Cycle

Fs Corre.
Ist Cycle

Fs Corre.
2nd Cycle

21.233.2

50

200

130

4.0 * N

2.6*N

33.239.2

85

170

170

2.0 * N

2.0*N

39.248.2

87

80

220

1.0 * N

2.5*N

2.56 *N

2.43 * N

Avg.

Design Recommendation Fs =

2.4 * N

End Bearing Resistance

At 1st Cycle, qb = 3,000 kPa
At 2nd Cycle, qb = 10,069 kPa
Average qb = 6500 kPa
Correlation factor for qb = 75* N

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Redesign of Pile Rebar Cage Lengths

The average pile lengths at CWRP were in excess of 50m

and maximum pile lengths exceeded 65 m.

Full length reinforcement required rebar cage fabrication in

multiple sections and then splicing over the drilled
boreholes. This activity could take up to 6 to 8 hours
depending on the pile length and size of rebar cage.

This has significant slowing down effect on piling

production while increasing the potential for borehole
collapse impacting the quality of bored piles.

The tension load on piles varied from about 23% to 33%

of compression loading as such it was concluded that the
full length reinforcement was not required to resist the
design loading on piles.

Reinforcement cage length were redesigned such that it

provided minimum factor of safety against tension loading
in excess of 3, were in multiples of 6 m length (i.e., 18 m,
24 m, 30 m and so on) thus eliminating wastage of
reinforcing bars during rebar cage fabrication.

The Piling at CWRP completed on time and redesign of

reinforcement lengths resulted in about 6 months of
schedule saving along with approximately S$5 Million in
cost savings.

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Summary & Overall Lessons Learnt

The Megaprojects present unique geotechnical challenges due to their complexity

and potential impact on the overall risk to the project schedule and budgets.

Effective management of these challenges requires empowered experienced

professionals familiar with design and construction aspects of the project.

Teamwork approach between Owner, Engineer and Contractor is critical for effective
management of geotechnical challenges and design optimizations as well as managing
design changes arising due to the variable subsurface conditions etc .

Comprehensive risk monitoring programs using performance monitoring approach

and contingency measures need to be in place for effective management of
geotechnical aspects .

Use of Language of Decision Makers while discussing the potential risks, available
options to manage them, associated costs and benefits while seeking senior
management / client endorsements is critical.

Finally, a culture of challenges and trust among the team members that allows
issues like these to be entrusted to the team to solve is critical. As an expert one can
solve issues that enhance the delivery but if the culture of the project does not allow
itall of these great solutions would not have been possible.

CWRP presented multiple geotechnical challenges that were successfully

managed without adverse impact to the project schedule and budget.

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References:
1. Parashar, S.P. & Sanmuganathan. D. (2005) Quality. Cost and Benefit Aspects of Site
Investigation Works A Changi water Reclamation Plant Project Experience. Proc. of
Underground Singapore 2005.
2. Parashar, S.P, Wong, I.H. & Sanmuganathan. D. (2005). Ground water Cut-off Wall at
Changi Water Reclamation Plant Project. Proc. of Underground Singapore 2005.
3. J. Chu, Parashar, S.P. and Sanmuganathan D.(2007). Comparison of Undrained Shear
Strength of Singapore Marine Clay determined by Laboratory and In-situ tests.
Proceedings of Underground Singapore. November 29-30, 2007.
4. Suresh Parashar, Roger Mitchell, Moh Wung Hee, Devaraj Sanmuganathan and Gordon
Nicholson (2007). Performance monitoring of deep shafts at Changi WRP Project,
Singapore. Proceedings of 7th International Symposium on Field Measurements in
Geomechanics, Boston, September 2007.

5. Suresh Parashar, Roger Mitchell, Moh Wung Hee, Devaraj Sanmuganathan, Ed Sloan
and Gordon Nicholson (2007). Performance monitoring of deep excavation at Changi
WRP Project, Singapore. Proceedings of 7th International Symposium on Field
Measurements in Geomechanics, Boston, September 2007.
6. Parashar, S.P., Chu J. and Sanmuganathan, D. (2008). Characterization of the
undrained shear strength of marine clay at Changi WRP Project, Singapore. Proceedings
of the 3rd International Conference on Site Characterization, April 1-4, 2008, Taipei,
Taiwan.

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THANK YOU.
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DFIMC 2012