AU2007100294A5 - Earth Retention and Piling Systems - Google Patents

Description

-1- EARTH RETENTION AND PILING SYSTEMS FIELD OF THE INVENTION This invention relates to soil stabilisation.

The invention also relates to the apparatus for stabilisation, and to soil structures stabilized by the apparatus.

BACKGROUND OF THE INVENTION Unstable soil structures, eg., comprising sand, clay, shale and/or broken rock, must be stabilized if they are to provide good foundations for building constructions.

Similarly, the structures must be stabilized where exposed wall areas are formed by excavation, eg., in open cut mines, mineshafts, and during the construction of building basements.

One excavation technique has used sheet piling and this has proved particularly successful in sandy or otherwise softer class soils. This technique is described in Australian Patent No. 631365.

The techniques to date have been primarily "passive" stabilization techniques designed to prevent localized collapsing of earth from the face of an exposed excavation wall. Over a period of time, however, subsidence can occur behind a passive retaining structure with consequent risks to the integrity of any building structure thereon.

In hard rock excavations such as underground mine shafts, it is common to stabilize and confine roof structures against collapse by the use of tensioned rock bolts which are anchored in boreholes by mechanical means and/or chemical or cementitious grouts. The anchors are spaced such that when tensioned, respective zones of compression in the rock mass overlap to form dynamic structural "beams" which are supported by the earth masses of opposing walls.

Where the rock mass is highly fractured, it is customary to employ steel "W" straps with rock bolts to spread the compressive load applied when the rock bolts are tensioned.

To restrain collapse of the rock walls in such mine shafts, a layer of steel mesh may be secured to the wall surface at intervals with rock bolts and then the wall -2surface is sprayed with "Shotcrete" to form a steel reinforced concrete shell. The rock bolts are inserted in the walls at much greater spacings than the roof as their purpose is merely to support the steel mesh and not to form overlapping zones of compression.

Other non-tensioned passive retaining systems are described in Australian patent applications 91307/82 and 16015/83 and Australian patent 571856 which all describe a form of "stitching" of earth structures with non-tensioned elements.

While certain aspects of the present invention are concerned primarily with stabilization and confinement of upright earth wall surfaces in open excavations, of softer earth, it is considered to be applicable in harder rock formations in certain instances.

Major problems associated with stabilization and confinement of excavation walls are the installation cost and bulk of the wall structure.

One structurally effective method for stabilization and confinement of excavated earth walls is the so-called continuous piling system. This system requires the drilling of overlapping bores to a required depth about the perimeter of a side and filling the bores with concrete to form a continuous concrete wall which, when cured, enable the earth contained within to be safely excavated.

The main problem with this system, apart from cost, is that it is u:;ually not possible to form the boreholes at the site boundary due to adjacent structures and thus the boreholes are located from 250-500mm within the boundary. After excavation, it is then necessary to erect an internal wall, spaced from the continuous piling to comply with hydrological requirements.

With such systems, an effective loss of usable space of up to 1 metre thick can occur around the boundary of the site.

Another commonly employed shoring system utilizes spaced soldier piles anchored to the earth formation with timber or otherwise shuttering extending therebetween.

This system is often a temporary structure which must subsequently be replaced with say a "Shotcrete" skin and a spaced internal wall-again with a substantial loss of useable space.

A compact system for stabilization and confinement of the walls of open excavations is described in Australian Patent Application No. 52382/86. In this system, elongate U-shaped members formed from steel rod are inserted free ends first into bore -3- Sholes in a short wall formed in a first stage of excavation. The U-shaped members; are full column grouted in their respective bore holes and the looped end of the U-shaped member is then bent through 900 to lie against the surface of the wall.

A further bore hole is then formed in the earth wall within the looped end of the U-shaped member and one or more further U-shaped members are then inserted into the bore hole and are full column grouted. This process is repeated to form a mesh-like array of interconnected U-shaped members which are then sprayed with Shotcrete to form a steel reinforced skin.

SUnlike the roof structure of a hard rock mine with reinforcing tensioned rock bolts, all of these prior art systems are passive in that they only react to resist collapse of an earth wall when localized outburst pressures due to subsidence or hydraulic pressures in wet clay occur.

The major problem associated with such passive systems is that they cannot be employed adjacent existing building structures due to the risk of subsidence in the earth structure supporting the existing building structure.

In all such passive systems, either localized or generalized subsidence will occur as the support structure takes up the subsidence pressures.

In a typical excavation of say 30-40 metres in depth, the first 5-10 metres of excavation may occur in a layer of soft sand or clay soil. The sandy or clay layer may then overlay a more stable earth layer of cemented "coffee rock" or a stiffer clay/shale. This layer in turn may be supported on a much more stable shale or weathered bedrock layer.

Accordingly, the risk of subsidence and/or collapse of the excavation wall is much greater in the upper layer of excavated earth than in the lower layers.

In sandy or unstable clay earth formations, it is common practice to employ sheet piling with earth anchors as a means of passive stabilization and confinement. While generally effective for its intended purpose, it is not always possible to employ sheet piling immediately adjacent the boundary of an existing building structure as the vibratory forces associated with driving the sheet piling into the earth formation can cause subsidence under the building structure. Moreover, it is frequently impossible to use earth anchors to anchor the sheet piling as much anchors would extend beyond the boundaries of the block being excavated into the adjoining property.

The present invention aims to provide useful and effective alternatives to prior art systems for stabilization and confinement of excavated earth structures to provide improved foundation systems for building structure.

In one aspect we have found there is provided a method of stabilization and confinement of excavated earth structures, said method comprising the steps of: excavating an earth structure to a predetermined depth; inserting earth anchors into a wall structure formed by excavation; tensioning each of said earth anchors to a required value against bearing members lying against the surface of the wall structure; interconnecting the exposed ends of selected earth anchors with reinforcing members; and applying a sprayable cementitious composition to the wall :surface to encapsulate part or all of said reinforcing members.

Suitably said boreholes are spaced at intervals such that when said earth anchors are tensioned respective--zones of compression associated with said bearing members overlap to form a compressed earth structure in the region of the exposed earth surface.

If required, the earth anchors may be grouted into the earth formation. A form of"deadman" anchor and/or a full column grouted anchor.

The reinforcing members may comprise steel rods and/or cable and/or steel reinforcing mesh or any combination thereof.

The steel rods and/or cable may be connected between adjacent anchors in columns, rows or a mesh array.

Suitably, the sprayable cementitious composition may include reinforcing fibres.

If required, the bearing members may comprise steel plates adapted to receivably locate said steel rods and/or cable and/or mesh.

If required, the steel rods and/or cable and/or mesh may be secured to said bearing plates by clamping means or by welding.

The bearing members associated with at least some of said earth anchors may comprise spaced soldier piles or sheet piles.

Preferably, the soldier piles or sheet piles are arranged as spaced pairs;.

If required, the bearing members may be selected members of a continuous sheet piling system.

Preferably, the sheet piles comprise at least partially flexible sheet piles. We have found that instead of forming the contoured members by a folding operation, substantial increases in strength can be obtained by roll forming those members. In this manner, comparative tests on folded vs roll-formed members show an increase in yield stress from about 350 MPa in folded steel to about 410 MPa in roll formed steel. Without being bound by theory, we believe that this is attributed to work hardening during the rollforming process.

According to the present invention there is provided a sheet piling member comprising a contoured member from steel in a roll forming process.

In a second aspect there is provided a method of forming a sheet piling member comprising the step of roll forming a contoured member from a steel sheet wherein said sheet piling member comprises the contoured member.

In a preferred embodiment of the present invention the contoured member is formed from 3mm steel, and preferably the steel is block mild steel.

The exposed ends of selected earth anchors in a first excavation step may be interconnected with reinforcing means to form a mesh like array and in one or more subsequent excavation steps, the exposed ends of selected earth anchors are interconnected with reinforcing means in rows, columns or diagonally.

Anchored sheet piling may be employed to stabilize and confine a second or subsequent excavation step.

Stabilising and confining earth structures to be excavated, may be performed by a method comprising the steps of: locating a plurality of pile members in said earth structure; conducting a first excavation step to a desired depth; -6anchoring said pile members to the earth structure therebehind with earth anchors; connecting exposed ends of selected earth anchors with reinforcing means; conducting a further excavation step to a desired depth; and repeating steps and until a desired excavation depth is reached.

The pile members may form spaced or continuous sheet piling.

Suitably, the pile members are produced by roll forming process and are located in the earth structure are spaced, eg., as spaced pairs, each said spaced pair being spaced from an adjacent spaced pair by a distance greater than the spacing between a spaced pair of pile members.

The spaced pile members may comprise steel sheet piling members with earth anchors extending into the earth structure via apertures in said sheet piling members.

Preferably, the sheet piling members are flexible sheet piles.

According to a still further aspect of the invention there is provided a building structure supported on anchored pilings formed using roll formed sheet piling and/or according to the abovementioned method steps.

The building structure may extend wholly above a ground surface or it may include a buoyant portion located below said ground surface.

Altemrnatively, the building structure may comprise a buoyant structure located substantially below a ground surface.

The buoyant structure may be anchored in an earth formation by anchored piles extending below a floor surface thereof and/or anchored piles extending to a ground surface.

In each of the piling aspects of the invention described above wherein a curable cementitious composition is incorporated in a pile column, fibre reinforcing may be employed.

Yet another aspect of the invention resides in a laminated sheet pile member comprising: a first roll formed sheet pile member is of predetermined length; and, at least one further roll formed sheet pile member laminated thereto, said further sheet pile member having a lower end adjacent a lower end of said first sheet pile member and an upper end located intermediate the opposed ends of said fist sheet pile member.

If required said laminated sheet pile member may include another sheet pile member laminated to said further sheet pile member, said another sheet pile member having a lower end adjacent a lower end of said further sheet pile member and an upper end intermediate the opposed ends of said further sheet pile member.

Preferably respective ends of said first sheet pile member and said at least one further sheet pile member are offset to form a tapered edge on said laminated sheet pile member.

Sheet pile members forming the laminated member may be joined by any suitable process such as edge welding, plug welding, mechanical fasteners, adhesives or the like or any combination thereof.

Preferably the laminated sheet pile member is corrosion resistant.

Still further aspects of the invention include apparatus for stabilizing and confining earth excavations, and earth excavations whenever confined and stabilized according to the various aspects of the invention.

As used herein, the term "flexible" as applied to sheet piling means sheet piling capable of deformation at least to a limited degree in both a longitudinal and transverse direction when earth anchors connected thereto are tensioned, the deformation in the sheet piling members causing localized compression in an earth structure therebehind.

The flexible sheet piling system is adapted to adjust or compensate for regions of differing compressibility in an earth structure.

BRIEF DESCRIPTION OF THE DRAWINGS In order that the various aspects of the invention may be more fully understood and put into practical effect, a number of preferred embodiments will be -8described with reference to the accompanying drawings, in which: FIG 1 shows schematically compression load distribution in a sheet piling wall.

FIG 2 shows a matrix of interconnected earth anchors according.

FIG 3 shows a bearing plate for interconnecting earth anchors.

FIG 4 shows an earth reinforcing system.

FIG 5 shows a method of tensioning reinforcing members connecting the free ends of earth anchors.

FIG 6 shows a partial view of a soldier pile and jointing element.

FIG 7 shows a bearing pile assembly.

FIG 8 shows a wall pile.

FIG 9 shows an excavation.

FIG 10 shows an excavation.

FIG 11 shows a laminated sheet pile.

FIG 12 shows an anchored pile.

FIGS 13 and 14 show applications of anchored piles.

FIG 15 shows a cross sectional view of test configurations for ultimate load capacity on single, double and triple sheet assemblies.

FIGS 16-19 show load vs deflection curves for the test configurations of FIG FIG 20 shows a bond beam construction.

DETAILED DESCRIPTION OF THE DRAWINGS In FIG 1, a plurality of contoured sheet piles 1 are first driven into an earth mass to a required depth to form a sheet steel barrier which is reinforced by the longitudinal contours. Overlapping edge flanges may be bolted together for extra strength if required.

However, the interlocking ribs and channels usually provide sufficient interconnection.

Through apertures formed in the sheet piling members, boreholes are formed in the earth structure 2 there behind. Depending upon the earth structure, an appropriate sand clay or shale anchor head 3 supported on a rigid steel rod 4 is inserted into the borehole.

A bearing plate 5, contoured to locate against the outer surface of the sheet piling member 1 and having a small slotted aperture to receive the free end 6 of the anchor rod 4 is placed over the anchor rod to abut the sheet piling member and form a closure to the aperture through which the head 3 of the anchor was inserted into the borehole.

A tapered washer (not shown) is then placed over the anchor rod to accommodate a downward and rearward insertion angle and then a nut 7 is tensioned to a predetermined torque on the threaded end of the anchor rod to engage the anchor head 3 in the earth structure and to induce compression in the earth structure between the region of the anchor head and the sheet piling.

In some cases, a mass of cementitious grout is pumped into the region of anchor head 3 to form a "deadman" 8 which provides greater anchorage in, for example, soft sandy soils. In this case, the anchor is pre-tensioned to, say 40-60kN to locate the anchor head and then the tension is released. When the grout is partially cured, tensioned is reapplied to about 40-60kN and then post tensioned to a desired value of between 60-120 I N when the grout has substantially cured.

It has been found that by using the geomechanical survey information normally required to determine slip planes and thus the depth of the anchor placement, it is possible to calculate the notional boundaries of compressed earth regions in the earth structure.

This information enables the calculation of anchor spacings and anchor nut torques to create an analogous situation with the reinforcement of hard rock roof structures in mine shafts or tunnels with mine roof bolts.

By careful calculation of anchor spacings and anchor nut torques, it is possible to create overlap between regions of compression 9 in the earth structure of adjacent anchors in the vicinity of the anchor heads and the sheet piling barrier where the anchor rod passes through.

This dynamic structure creates spaced bands of compressed earth structure which serve to reinforce the earth structure adjacent an excavation and otherwise to assist in its confinement.

Unlike a mine roof/bolt which creates a zone of compression over its entire length, the anchor bolts induce zones of compression adjacent its opposed ends with a region of unaffected earth therebetween. Moreover, while mine roof bolts form a stressed "beam" which extends transversely of a shaft, that "beam" is structurally supported by passive earth masses in the shaft walls.

In a typically rectangular excavation aperture, the method according to the invention forms an upright rectangular boundary of earth reinforced by continuous compression throughout but otherwise confined by the sheet piling against movement.

This dynamic structure is particularly important in soft sandy soils which are prone to subsidence or hydraulic clay soils which are subjected to expansion or contraction depending on water content.

The flexible sheet piling described above can be reinforced further by the subsequent connection of reinforcing rods across the exposed face of the continuous sheet piling structure. The reinforcing rods may be attached to the sheet piles and/or the anchor ends in any suitable manner, eg., by welding, brackets or the like.

After say spaced horizontal reinforcing rods are attached across the face of the sheet piling, bands of Shotcrete or the like may be sprayed over the rods to encapsulate them to form spaced reinforced concrete walers across the exposed surface of the sheet piling structure.

Instead of or in addition to the spaced horizontal reinforcing rods, steel reinforcing mesh, vertical and/or inclined reinforcing rods may be employed.

It is considered a particular advantage of the present invention to use sheet piling having substantially uniform generally shaped ribs and troughs to aid in substantially even distribution of compressive forces throughout the compressed earth layer adjacent the sheet piling.

FIG 2 shows an alternative embodiment of the invention which is suitable both for soft unstable earth masses or relatively stable earth masses.

In certain circumstances, it is not possible to use the above method in stabilization and confinement of an earth excavation where the excavation site is -11- (Z immediately adjacent an existing building structure supported on a highly unstable earth mass. In such circumstances, the mere vibration of the sheet piles into the ground can cause subsidence under the existing building structure before excavation commences, let alone before the earth mass may be stabilized by compression.

In the circumstances, it has been discovered that it is possible to excavate to a depth of 1-1. 5 metres and then insert a row of tensioned earth anchors 10 at predetermined spacings.

Excavation is then continued for a further 1-1.5 metres and a second row of Stensioned earth anchors are inserted at appropriate spacings.

After excavation, a further depth of about 1-1.5 metres and inserting tensioned earth anchors, steel reinforcing rods 11 are connected between the free ends of the anchor rods. Optionally, a layer of steel reinforcing mesh (not shown) is then secured over the mesh-like structure of reinforcing rods.

Shotcrete containing polypropylene fibre reinforcing is then sprayed over the structure to encapsulate the reinforcing members attached to the free ends of the anchor rods.

Once the upper unstable earth layer has been confined and reinforced, it may then be possible to drive sheet piling down to a desired depth in a conventional manner without fear of subsidence of an adjacent earth mass.

Alternatively, as shown, the excavation in the more stable earth mass may be continued for a further 3-4 metres and tensioned earth anchors may be inserted at the same or different spacings as those above and they may be tensioned by the same of different nut torque depending upon the geomechanics of the subsequent earth layer.

In all cases, the earth anchors are tensioned against a bearing plate 12 lying against the surface of the excavated earth.

As shown, only parallel rows of reinforcing rods are required in the more stable earth mass of the subsequent excavation. Shotcrete 13 may be applied only to encapsulate the rods or it may be applied over the entire surface of the exposed wall to form a blinding layer. If required, a reinforcing mesh (not shown) may also be used in conjunction with the reinforcing rods 11.

-12- FIG 3 shows a preferred form of bearing plate 12 of the type employed in the structure shown in FIG 2.

The plate 12 comprises a planar portion 31 having a slotted aperture (not shown) to receive the free threaded end 14 of an anchor rod. As the anchor rod is inserted into the earth mass at an angle relative to the horizontal, a tapered washer 15 is provided for an anchor nut 16 to bear upon.

Located across the top of bearing plate 12 is a tubular housing 17 to slidingly receive a reinforcing rod 18.

Reinforcing rod 18, once located in housing 17, may be secured by welding at the ends of the housing or by a clamp means such as a threaded bolt extending through a threaded aperture in the housing wall.

FIGS 4 and 5 show an alternative earth reinforcing and confining system according to the invention.

In this example, sheet pile members 20 are located in an earth mass to a required depth as spaced pairs. The spaced pairs of sheet pile members as shown will provide sufficient support to permit at least a shallow excavation in relatively unstable earth masses.

Earth anchors 21 are progressively installed through the sheet piling as described with reference to FIG 1 and the anchors are tensioned by nuts 22 bearing on tapered washers 23 in turn bearing 'on contoured bearing plates 24 located in a trough of the sheet pile members 20. This adds stability to the earth mass. In this embodiment, the free ends 25 of the anchor rods 26 extend from the base 27 of the trough where they extend through the sheet piling to a position just beyond the tops of adjacent ribs 28.

Reinforcing rods 30 are then located against the tops of ribs 28 of the sheet piling and the rods may be tack welded or otherwise secured to the other pile members over which the rods pass. For example, the rods 30 may be secured to respective sheet pile members 27 by means of bearing plates 29 of the type illustrated in FIG 3 and depending on the nature of the earth structure, rods 30 may be tensioned or untensioned. If tensioning is required, nuts 22a are torqued to a predetermined value to tension the rods 30 which then assume the position shown in phantom between the tops of adjacent ribs 28.

-13- In the event that the exposed surface of the earth retaining and confining system is to be sprayed with Shotcrete or the like and then screeded to form a finished wall surface 32 as shown in phantom in FIG 6, it is important that there is minimum protrusion beyond the tops of adjacent ribs 28 as regulations usually require a minimum thickness of coverage over steel members.

As shown in FIG 6, this may be achieved by a bracket 33 having a jaw 34 which engages over reinforcing rod 35 and which is secured to anchor rod 26 by a nut 36. In this case, the anchor rod end 37 is terminated below the levels of adjacent rib tops 28 and tensioning of rod 35 is carried out only if required.

If required, steel mesh 32 shown in FIG 4 may also be used in conjunction with reinforcing rods 30 and the entire structure may then be sprayed with Shotcrete to encapsulate the reinforcing members and to form a blinding layer in the spaces therebetween.

When the Shotcrete has at least partially cured, excavation may then continue with placement of further reinforcing members as described above.

The above described method is considered to be particularly advantageous over prior art earth stabilization and confinement systems due to substantially reduced labour and materials requirements while maintaining sufficient integrity for a temporary wall structure.

By utilizing a borehole drill fitted with spaced drill bits, the holes for two, three or even four adjacent anchors may be drilled simultaneously, thereby saving considerable time in installation of earth containing and retention systems according to the invention.

It is considered that the structure shown generally in FIG 4 utilizes up to less earth anchors than equivalent systems and overall, consumes less steel than continuous sheet piling systems.

Where circumstances mitigate against the installation of the spaced sheet pile "soldiers", spaced boreholes can be prepared to receive cast in situ reinforced concrete piles.

These concrete piles may be supported by anchors attached to brackets on the concrete columns or by a saddle bracket extending between adjacent concrete piles.

-14- The following examples further illustrate the flexibility and the broad applicability of the stabilization and confinement systems according to the invention.

Examples To "stitch" together a rock formation, a plurality of holes are drilled in a matrix configuration, preferably three rows deep. Rock anchors are inserted in the holes ;'grout is pumped into the holes and the anchors are pre-tensioned when the grout has partially set.

Reinforcing plates are provided on the anchor rods, and each reinforcing plate has a tubular body dimensioned to freely receive reinforcing rods passing through the bodies. Reinforcing rods interconnect the reinforcing plates on the anchors in columns, rows and/or diagonally and it is preferable that, at a "join", adjacent reinforcing rods pass through the tubular body of a reinforcing plate and overlap for, eg., 0.5 to 1 metre. The reinforcing rods are then pre-tensioned, eg., using tensioning nuts at respective ends of the rods.

The reinforcing rods may be tack-welded to the reinforcing plates, and then reinforcing mesh is fixed to the reinforcing rods, preferably interposed between the reinforcing rods and the exposed face of the rock wall. The anchors are then post tensioned to force the reinforcing mesh (and reinforcing rods) into compression against the exposed face of the rock formation. This compresses the exposed face inwardly, while the zones around the anchors are compressed so that the total rock structure is placed into compression. Initially, the reinforcing is "dynamic", but when the anchors have been tensioned, the resulting reinforcing is passive.

Example 2 In sandy, clay and/or shale soil structures, after the reinforcing mesh has been erected by the method of Example 1, the reinforcing mesh is sprayed with concrete to form a wall. It is preferable that the concrete incorporate polymeric reinforcing fibres of the type sold under the trade mark "FIBREMESH") and the concrete is allowed to set before the anchors are post-tensioned.

A binding layer of concrete may be sprayed onto the exposed wall surfaces either before or after the anchors are inserted, but before the reinforcing rods and reinforcing mesh are applied, to minimise likelihood of failure of the exposed wall surface while the stabilization method is being carried out.

2 Example 3 In sand, clay or shale, soldier piles or sheet piles are erected in front of the exposed wall face and supported by the anchors, and the reinforcing steel mesh is optionally connected to the sheet or soldier piles. The use of the sheet or soldier piles has the advantage N, that the number of anchors required to support a particular soil structure can be reduced, eg., by up to Example 4 N, To enable excavation in an unstable soil structure, pairs of holes are drilled in the structure, substantially along the line to be excavated, at spaced intervals. Reinforcing steel is placed in the holes, and concrete or grout, preferably containing the polymeric reinforcing fibres, is pumped into the holes to cast the piles in situ.

When the piles have set, the structure is excavated, eg., to a depth of 1-2 metres and an anchor is provided to support each pair of piles in the excavated zone.

(Preferably, holes are drilled into the soil structure, the anchors are inserted and grouted, the anchors are pre-tensioned, and then post-tensioned after the grout has set.) Reinforcing mesh and/or rods are provided between the adjacent pairs of piles and concrete (containing polymeric reinforcing fibres) is sprayed onto the reinforcing mesh and allowed to set. The excavation that is carried out to a further depth of, eg., 2 metres, further anchors are installed, reinforcing mesh erected and concrete sprayed as hereinbefore described. These steps are repeated until the excavation reaches its desired depth. (NB It is preferable that the piles extend at least 1. 5 metres below the desired depth of excavation.) Example Where the soil formation is primarily rock, it is optional whether or not the concrete is sprayed onto the reinforcing mesh.

Example 6 A binding wall layer of concrete may be sprayed onto the exposed wall before the reinforcing mesh is erected in Examples 4 and Example 7 -16- In expansive soils, eg., clay, blocks of foam may be fixed to the exposed wall face (or blinding wall layer) and be interposed between the exposed wall face an the reinforcing material to accommodate any expansion or contraction of the soil as the soil is either watered or de-watered. (Some de-watering of the soil will occur when the anchors are post-tensioned.) Example 8 In an alternative embodiment, the foam material may be sprayed onto the exposed wall or blinding layer before the reinforcing mesh is erected.

At the base of the excavation, conventional footings for a building may be cast, and it is preferable that the base of the wall be tied to the footings to form water-proof unitary structure.

Example 9 For deep excavations, eg., greater than 10 metres, excavation can be carried out in a series of steps, where each seceding wall is "stepped out "from the wall above it and the top of one wall is tied to the bottom of the wall above it.

Example Where the unstable soil overlies the stable soil formation, the excavation method may be carried out until the stable soil formation is reached, and then the base of the wall may be tied to sheet piles (or other piles) driven into the stable soil formation.

The methods hereinbefore described enable unstable or poor quality soil formation to be stabilized and/or excavated and the resultant soil structure is much stronger and more stable than the soil structure stabilized by existing stabilization methods where the soil structure is not compressed to overcome any weaknesses or voids in the structure).

The examples described are by way of illustrative example only and various changes and modifications may be made thereto without departing from the broad scope of the invention.

FIG 6 shows schematically a soldier pile 40 according to a further aspect of the invention.

Soldier pile 40 comprises centre flanges 41, 42 and outer flange:s 43, 44 and -17the cross sectional shape of the pile 40 is complementary to corrugated sheet piling of the 2 type described in Australian Patent No. 631365 and which is preferably employed with the invention.

After inserting sheet piling (not shown) to a required depth in an earth formation, soldier piles 40 are driven, at spaced intervals, into the earth formation against the surface of the sheet piling to provide a support therefor where it is not possible to O support the sheet piling by such earth anchors.

As shown, the soldier pile 40 may be made up of a number of elements secured together by a joining element 45 having a cross-sectional shape complementary to the soldier piler contour.

Elements 40a, 40b (and so on) are progressively joined as the soldier pile is driven into the earth formation by, for example, high frequency vibration. Joining element is secured to the respective lower and upper ends of elements 40a, 40b by bolts 46 or the like.

When the soldier pile 40 is driven into the earth formation to a required depth, it may be secured to the sheet piling (not shown) by bolts, plug welding or the like via punched apertures 47.

FIG 7 shows a bearing pile 50 which may be utilised in accordance with the invention.

Bearing pile 50 comprises a pair of pressed, folded or cold rolled metal sheets having a folded central web 51 and opposite side flanges 52 secured together by bolts (not shown) or byjointing welding via apertures 53.

Like the soldier pile of FIG 6, the bearing pile 50 may be constructed of elements 50a, 50b (and so on) sequentially joined together by joining elements 54 as the pile is driven into the earth formation.

The bearing pile may be of any suitable cross sectional shape eg. round or polygonal and may comprise cylindrical elements if required.

FIG 8 shows a wall pile 60 in accordance with yet another aspect of the invention.

-18- Wall pile 60 comprises a generally U-shaped central web with upturned side flanges 60 shaped to nest in the region between central web 40a and respective side flanges 43, 44 of a soldier pile 40 is shown in FIG 6.

After a soldier pile 40 is driven into an earth formation in nesting contact with a sheet pile formation 61 (shown in phantom), wall pile 60 is driven into the earth formation in nesting engagement with the soldier pile 40 to provide additional support of the sheet piling during and after excavation of earth.

As an alternative to wall pile 60, there may be used hollow triangular cross section piles of the type described in International Patent Application PCT/AU97/00514 and illustrated in Figures 1 and 2 thereof.

Again, like the pile members of FIGS 6, 7 and 8, these triangular piles may be made up of elements joined by a joining member of complementary triangular cross section.

The triangular piles of PCT/AU97/00514 have an apex portion which nests directly into the valley portions of the sheet piling system and as such my function directly as soldier piles without the need for the soldier piles of FIG 6.

If required, the triangular cross section piles may be of enlarged cross section such that the base portion, opposite the apex portion, lies in a plane spaced from the front surface of the sheet piling.

FIG 9 shows one method of stabilising and confining an earth excavation.

In FIG 9 the earth formation to be excavated comprises a layer of sand 70 and a layer of more stable earth 71 such as shale or clay/shale supported on a bedrock interface 72.

Initially corrugated interlocking single or laminated sheet piling members 73 are driven into the earth formation below the sand/shale interface.

Soldier piles 74 of the type shown in FIG 6 are then driven to a desired depth into the earth formation in contact with the sheet piling 73. If required, wall piles 75 (shown in phantom) of the type shown in FIG 8 or of a triangular cross section as described above then may be driven into the earth formation to a desired depth, in this case down to the bed rock layer 72.

-19- Thereafter excavation is carried out with the unstable sand layer '70 being supported and confined by sheet piling 73, itself being supported by soldier piles 74 at spaced intervals and, if required wall piles If the excavation is to be carried out directly adjacent an existing building structure whereby the use of earth anchors is precluded, the soldier pile/wall pile combination will provide sufficient support for the sheet piling.

Where the use of earth anchors is not precluded, the excavation wall may be supported by the sheet piling 73 and soldier piles 74 with earth anchors 76.

If it is intended to utilise the exposed excavation wall as, say, a direct wall for a basement, wall piles 75 may then be removed and the exposed wall could then be finished by applying a blinder layer of sprayable cementitious composition over a metal mesh between the soldier piles below the level of the sheet piling. The entire wall surface may then be finished in the manner described in our Australian Patent No. 682453.

Alternatively, hollow wall piles 75 may be left in place and secured to the soldier piles 74 by spaced welds, bolts or the like.

Any earth remaining in the hollow interior of wall pile 75 below the excavation floor 77 may then be removed by blasting high pressure air or water via a nozzle lowered into the pile interior.

The pile 75 may then be partially filled with compacted sand or earth and a concrete cap 78 containing steel starter bars 79 is formed in the upper part of the pile.

A concrete bond beam 80 tied to the piles 75 via starter bars 79 may then be formed about the upper periphery of the excavation to provide footings for a building structure to be erected thereon.

To support a floor slab 81 poured on the excavation floor 77, bearing piles 82 of the type illustrated in FIG 7 may be driven down to bedrock layer 72 and any earth therein removed by air or water blasting. Thereafter, the interior of the pile 82 is partially filled with compacted sand and a concrete cap 84 containing starter bars 85 is then formed in the top portion of pile 82.

Concrete slab floor 81 when poured is then tied to and supported by bearing piles 82.

If required, longer bearing piles 86 containing compacted sand 87 and a concrete cap 88 with starter bars 89 may extend from the bedrock surface 72 through the floor slab 81 to support a suspended floor slab 90 (shown in phantom).

As indicated previously, unitary cylindrical bearing piles may be employed with the method rather than the two-piece piles of FIG 7.

FIG 10 shows an alternative embodiment of the method described with reference to FIG 9.

As with the soil stabilisation and confining system of FIG 9, sheet piling 100 is driven into an earth formation such that the lower end 101 of the sheet piling 100 is located below the interface 102 between an unstable sandy layer 103 and a layer of stable shale or clay/shale 104 and also below excavation floor 113.

Thereafter, spaced soldier piles 105 of the type illustrated in FIG 6 are driven into the earth formation with the upper portion thereof nested with the corrugated sheet piling 100.

Wall piles 106, again nested against the soldier pile 105 are driven into the earth formation with the lower ends 107 thereof spaced above a bedrock layer 108.

Earth is then removed from within the hollow interior of wall piles 106 by high pressure air or water blasting and a hollow cavity 109 below the wall piles 106 is created by the fluid blasting process.

A flowable curable cementitious mass is then pumped under pressure into the interior of wall piles 106 until it fills the hollow cavities 109 below the wall piles and fills at least the lower portion 110 of each wall pile 106. If required, steel reinforcing bars (not shown) may extend between the cementitious mass in the lower portion 110 of the: wall piles and the cementitious mass 111 occupying the hollow cavities 109.

When the cementitious mass 111 cures it provides a foundation or footing to support loads applied on wall piles 106 and thus obviates the need for excessively long wall piles where the bed rock surface 108 is very deep in the earth formation.

After excavation is completed and before the floor slab 112 is poured on the excavation floor 1 13, bearing piles 14 are driven into the earth formation and the earth contained in the piles is removed by air or water blasting.

-21 As with the wall piles 106, a hollow cavity 115 is formed beneath each bearing pile 114 where the lower end thereof is not resting on the bedrock surface 108.

Again, the hollow cavities 115 and the hollow interior of bearing piles 114 are filled with a flowable curable cementitious mass pumped therein under pressure and, if required, reinforcing bars 116 may extend from the footing or foundations 117 through the bearing piles 114 to protrude therefrom to the floor slab 112 when it is poured.

After the floor slab 112 has been poured, the portion of wall pile 106 extending above the floor surface is removed by cutting the wall piles 106 with an oxyacetylene torch or the like at floor level and then removing the severed portion.

Thereafter, the wall surface of the excavation may be completed by spraying a cementitious binder layer onto steel mesh reinforcing between the soldier piles 106 and then applying a screeded cementitious surface over the entire exposed surface in accordance with the method described in our Australian Patent 682453.

Piles of the type shown in FIG 7 and as shown generally in FIGS 9 and 10 as bearing piles have been shown to possess significant load bearing capacity when filled with a cementitious grout and a steel reinforcing cage.

Similarly, the performance of triangular section piles of the type described in our co-pending International Patent Application PCT/AU97/00514 also can be greatly improved by the use of a cementitious core with steel reinforcing.

Table 1 below represents the ultimate binding capacities of triangular pile sections using differing steel wall thicknesses and differing low strength concrete grouts.

The steel reinforcing cage comprised three Y12 bars equally spaced in the section with R6 ties at 300mm intervals.

TABLE 1 PURE BENDING (AXIAL LOAD 0) Concrete Grout Concrete Grout 25 MPa 32 MPa Wall bo Section Section 4M 2 x(kN.m) (M 2 x(N.m) thickness (mm) base height width (base to Grout 3Y12 Grout 3Y12 S_ apex) 22 3 27.4 188 112 9.8 22.5 9.8 24.5 3/4 27.4 186 111 11.7 26.4 11.7 28.4 4 27 186 110 12.9 28.7 12.9 30.7 Table 2 below represents calculated load strengths of an isosceles triangular section pile having a base width of 186mm and a height (base to apex) of 110mrm with differing reinforcement capacity and concrete gout strength.

Significantly these calculated load capacities do not allow for the contribution of the triangular section steel outer casing.

TABLE 2 Casing Pile Size Concrete Pile Capacity Reinforcement thickness Strength (Working Load) ManTe (mm) (mm (MPa) 3 186x110 32 MPa 17T 3Y12 R6@300 3 186x110 32 MPa 19T 3Y16 R6@300 3 186x110 32 MPa 21T 3Y20 R6@300 3/4 186x110 32 MPa 17T 3YI2 R6@300 3/4 186x110 32 MPa 19T 3Y16 R6@300 3/4 186x110 32 MPa 21T 3Y20 R6@300 4 186x110 32 MPa 17T 3Y12 R6@300 4 186x110 32 MPa 191 3Y16 R6@300 4 186x110 32MIA 21T 3Y20 R.6@300 3 186x110 40OMPa 21T 3Y12 R.6@300 3 186x110 40OMPa 23T 3Y16 R6@300 3 186x110 40OMPa 25T 3Y20 B,6@300 3/4 186x110 4OMI~a 21T 3Y12 R6@300 3/4 186x110 40OMPa 23T 3Y16 R6@300 3/4 186x110 40OMPa 25T 3Y20 R6@300 4 186x110 40OMPa 21T 3Y12 R6@300 4 186xI10 40OMPa 23T 3Y16 R6@300 4 186x110 40 MPa 25T 3Y20 R6@300 -23- Notes: (1) The geotechnical capacity of the pile will depend on the local soil conditions.

(The local soil conditions need to be checked to confirm pile capacity) The pile loads are WORKING LOADS (not factored).

The pile loads assume no pile eccentricity.

Pile capacities do not include additional capacity due to steel casing.

Table 3 below shows pile capacity for an isosceles triangular section pile width of 275mm, a height (base to apex) of 138mm and a steel wall thickness having a base of 4mm.

TABLE 3 Pile Size Concrete Pile Capacity Reinforcement Strength (Working Load) Main Ties (mm) (MPa) (Tonnes) 275x138 32 MPa 26T 3Y12 R6@300 275x138 32 MPa 28T 3Y16 R6@300 275x138 32 MPa 31T 3Y20 R6(@300 275x138 32 MPa 33T 3Y12 R6@300 275x138 32 MPa 35T 3Y16 R6@300 275x138 32 MPa 37T 3Y20 R6@300 Table 4 below shows load capacity of a square section pile of the type shown in FIG 7 having an external section measuring 230mm x 230mm, a Wall thickness of 3mm and with varying concrete grout and reinforcement strengths. The steel reinforcing bars are equally spaced and lie along intersections between opposite corers.

TABLE 4 Pile Size Concrete Pile Capacity Reinforcement Strength (Working Load) Main Ties (mm) (MPa) (Tonnes) 230x230 230x230 32 MPa 32 MPa 65T 70T 4Y12 4Y16 R6@300 R6@300 24 771 86T 230x230 230x230 32 MlPa 32 MPa 4Y20 4Y24 R6@300 R6()300 230x230 4OMPa 78T 4Y12 R6@300 230x230 40OMPa 83T 4Y16 R6@300 230x230 40OMPa 91T 4Y20 R6@D300 230x230 40OMPa lOOT 4Y24 6D30 230x230 50OMPa 95T 4Y12 R6@D300 230x230 50OMPa IOIT 4Y16 R6@D300 230x230 50 MPa 108T 4Y20 R6@300 230x230 50OMPa 117T 4Y24 R@)0 Similarly Table 5 represents a square section pile measuring 400mm x 400mm and a wall thickness of 4mm. Variously, combinations of spaced reinforcing bars are positioned to lie along the intersections between opposite corners approximately in from the inner wall surface and/or centrally of the external casing walls, again about in from the inner walls.

TABLE Pile Size Concrete Pile Capacity Reinforcement Strength (Working Load) ManTe (mm) (MPa) (Tonnes) 400x400 32 MPa 175T 4x16 R1I@300 400x4O0 32 MlPa 185T 4Y20 RIO@300 400x400 32 MPa 195T 8Y18 2xRlO0@300 400x400 32 MPa 1951 4Y24 RlO@300 400x400 32 MPa 2101 8Y20 2xRIO@300 400x4O0 32 MPa 230T 8Y24/4Y32 2xRlO@300 400x400 400x4O0 400x400 400x400 400x400 40 MPa 40 MPa 40 MPa 40 MPa 40 MPa 2001 2201 2301 2301 255T 4x 16 4Y20 8Y 18 4Y24 8Y20 Rl O@300 Rl O@300 2xR 1 0@300 Rl0@300 2xR 1 @300 Pile Size Concrete Pile Capacity Reinforcement Strength (Working Load) Main Ties (mm) (MPa) (Tonnes) 400x400 40 MPa 260T 8Y24/4Y32 2xRl0@300 400x400 50 MPa 260T 4x16 R10@300 400x400 50 MPa 280T 4Y20 R10@300 400x400 50 MPa 290T 8Y18 2xR10@300 400x400 50 MPa 290T 4Y24 R10@300 400x400 50 MPa 310T 8Y20 2xR10@300 400x400 50 MPa 325T 8Y24/4Y32 2xR10@300 In the piles of Tables 4 additional capacity of the steel casings.

and 5, the calculations do not take into account the FIG 11 shows yet another aspect of the invention which can be employed with other aspects of the invention requiring sheet piling.

Generally speaking, the use of flexible sheet piling of, say, 3 mm in thickness according to the earlier described aspects is very effective for its intended purpose provided sufficient earth anchors are employed to reinforce the corrugated sheet piling structure.

In order to insert an earth anchor, it is first necessary to cul an aperture in the sheet piling with an oxy-acetylene torch or the like and then drill a borehole to receive an earth anchor. Depending on soil conditions, the earth anchor may be driven directly into the soil by impact or high frequency vibration.

After the anchor is inserted it is tensioned against a bearing plate by a threaded nut.

As insertion of earth anchors is a relatively expensive exercise it would be of economic significance if the number of earth anchors could be reduced without affecting the structural integrity of a sheet piling installation.

In FIG 11 there is shown a laminated sheet pile 130 having a corrugated cross section wherein adjacent faces are at about 90° to each other.

The laminated pile typically comprises a full length pile member 131, 3mm -26thick and say, 12m in length and laminated thereto are further 3mm nested pile members 132, 133 of say 9m and 6m in length respectively.

The lower end or toe 134 of the laminated sheet is tapered by offsetting the laminates 132, 133 by an amount approximately equal to the sheet thickness (3mm) and then fillet welding the sheets together across the free edges.

Between the upper ground surface 135 and the floor 136 of excavation 137 lies a slip plane 138 which has an angle dependent upon the soil type and structure.

After the sheet piling 130 is driven into the earth to form a support for an excavated wall, excavation occurs progressively with earth anchors being inserted at appropriate excavation depths and spacings across the interlocked sheet piling wall.

As shown a first earth anchor 139 may be inserted at an excavation depth of Im, and successive anchors 140, 141 and 142 at depths of4m, 7m and 9m and respectively tensioned to 50kN, 65kN and 100kN.

The added stiffness of the laminated sheet towards the level of the floor of the excavation, where the compressive load of the earth therebehind is greatest, permits far less earth anchors to be employed.

In a typical excavation of from 10-12m in depth the number of earth anchors may be halved with resultant considerable cost savings.

Moreover, as the thickness of the laminated pile is greatest at the base of the excavation, the extent to which the sheet piling must extend into the earth below the excavation floor (typically from 1-3m) may be reduced with a further saving in steel.

The laminated pile is preferably coated with a corrosion resistant coating such as galvanising, zinc plating, a tar epoxy compound or other synthetic resin.

The layers of the steel laminate may be connected by edge welding, plug welding, bolting or by adhesive or any combination thereof.

Depending upon the soil type, the laminated structure may comprise contoured sheets of steel or fibre reinforced plastics material or a combination thereof.

FIG 1 Ila shows schematically the relationship between sheet piling thickness and inertia moment and Table 6 shows specification and sectional parameters.

-27- TABLE 6 Section Thickness Profile Mass Moment of Section kg/m of kg/m 2 of Inertia Modules (Code) (mm) (mm) single pile wall (cm 4 (cm3/m) SP215 2 150 18.90 29.50 1378 169 SP315 3 150 28.26 44.30 2045 249 SP415 4 151 37.68 59.00 2767 333 SP515 5 152 47.16 73.80 3598 424 SP615 6 153 56.52 88.60 4600 527 SP715 7 154 65.94 103.30 5845 647 SP815 8 155 75.36 118.00 7426 788 SP915 9 156 84.84 132.80 9456 959 SP115 10 157 94.32 147.60 12084 1165 FIG 12 shows still a further embodiment of the invention.

In FIG 12, an anchored pile 140 is constructed by forming a borehole 141 in an earth formation 142 down to a base layer 143 and then filling the borehole with a low strength cementitious grout 144 of say 20-40 mPa.

A hexagonal section reinforcing cage 145 having say Y16 bars and R6 ties is then lowered into the grout while it is still fluid. The cage is positioned centrally of the grout column and rests on the base layer 143 forming the floor of the column.

After the grout is allowed to cure for 3-4 days a 150mm borehole 146 is formed down the centre of the reinforcing cage and through the base layer 143.

An earth anchor 147 with associated tension rod 148 is then inserted in borehole 146 and anchor 147 is anchored in the surrounding earth formation 149 by placing an apertured plate (not shown) over the top threaded end 150 of anchor rod 148 and then tensioning a threaded nut (not shown) to engage the flukes 151 of anchor 147 in the wall of borehole 146.

After releasing the nut and bearing plate, a further quantity of grout is placed in the lower portion of borehole 146 to fully encapsulate anchor 147.

-28- The grout is allowed to cure for 3-4 days after which the anchor rod 148 is again tensioned to ensure anchoring of anchor 147.

The pile is then completed by filling the remainder of borehole 146 with grout and allowing it to cure.

In an alternative embodiment, instead of a reinforcing cage, a triangular section pile of our co-pending application PCT/AU97/00514 may be employed or a combination of triangular section pile with reinforcing bars.

Table 7 shows calculated working capacities for the combined compression/tension piles according to this aspect of the invention.

TABLE 7 Description Pile Concrete Reinforcement Pile Capacity Size Strength (Working Load) (mm) (MPa) 6Y16 TP3/3 TP4/4 (Tonnes) 350 Diameter 350 32MPa Yes No No 116T Pile with 6Y16 bars 350 Diameter 350 32MPa Yes Yes No 149T Pile with 6Y16 bars and TP3/3 350 Diameter 350 32MPa Yes No Yes 155T Pile with 6Y16 bars and TP4/4 It should be noted that the calculations in Table 7 do not take account of any of the steel reinforcing or anchoring elements.

Anchored piles of this aspect of the invention will have application where a structure supported on the piles can apply both tension and compression to the piling.

Tension for example could occur due to wind uplift on the supported structure, earthquakes or even buoyant forces from subterranean water.

FIG 13 shows schematically a building structure 160 supported at ground level 161 on anchored piles 162 of the type described with reference to FIG 12.

Below ground level 161 is a two level basement area 163 surrounded by a waterproof wall 164 and a waterproof floor 165 also supported in its central area by -29- N anchored piles 162.

2 Piles 162 rest on a foundation layer interface (bedrock) 166 with anchors 167 anchored therein.

In some soil conditions such as poorly drained soils and in particular clay soils, the buoyant uplift on the building structure 160 can cause movement in the structure Swhen the soil becomes waterlogged.

Of even greater concern is that if such a structure was to be built on a hydraulic clay soil, prolonged dry periods can cause substantial shrinkage of the soil with Sconsequent subsidence of the structure.

If then followed by very wet conditions, the combined effects of buoyancy and the hydraulic expansion of the clay can cause very high uplift forces.

FIG 14 shows another application of anchored piles.

In FIG 14 there is illustrated schematically an underground liquid storage vessel 170 for water, fuel or other liquids.

Vessel 170 may be constructed from sheet piling according to the invention and lined with screeded cementitious grout to form a fluid tight container. A lid or roof 171 may comprise a suspended concrete slab and have appropriate conduits 172, 173 fbr filling, emptyings or as a breather.

The vessel is constructed as generally described above by installation of corrugated sheet piling followed by excavation.

Before forming floor slab 174 anchored piles 175 are formed by drilling boreholes and formation of cavities 176 thereunder by high pressure fluid excavation.

Fluid cementitious grout is pumped into the cavities 176 and earth or other anchors 177 are inserted with their respective anchoring heads anchored in the cementitous mass 178 in each cavity. The anchor rods 179 extend beyond the upper openings of the boreholes for connection to floor and/or wall reinforcing members (not shown).

The boreholes are then filled with cementitious grout before pouring of the floor slab 174 and screeding of walls 180.

When completed, vessel 170 may be covered with a layer of earth 181 if required.

Even when the vessel 170 is filled with say liquid fuel, the specific lgavity is sufficiently less than water in the surrounding earth mass such that uplift can occur.

The main advantage of the structure as shown with anchored piles is realised when the vessel is empty or near empty when the buoyant uplift forces in waterlogged earth could dislodge the vessel.

Anchored piles according to the invention will have particular application to the construction of swimming pools and the like.

Throughout the above description, reference is made to contoured sheet piling members, soldier pile members, wall piles and hollow or grout filled load bearing piles formed from elements having generally complementary surface contours.

Typically, these members may be formed from 3mm thick black raild steel sheet in a brake press or other folding operation.

It has now been found that instead of forming the contoured members by a folding operation, substantial increases in strength can be obtained by roll forming those members. In this manner, comparative tests on folded vs roll-formed members show an increase in yield stress from about 350 MPa in folded steel to about 410 MPa in roll formed steel. Without being bound by; theory, we believe that this is attributed to work hardening during the roll-forming process.

The following discussion relates to a determination of ultimate load capacity of roll formed sheet piling members employed in various aspects of the invention.

Three series of tests were conducted single, double and triple panel configurations shown generally in FIG 15. Each full sheet was 3000mm long x 915mm wide x 3mm thick having an upper profile of three peaks and two valleys. The distance from peak to valley was approximately 150mm.

The sheet configurations were supported as simple beams with the end reactions formed to the profile of the sheets. Sand was placed on the central section giving a bed the width of the specimen by 1 metre long and to a height of 50mm above the peaks.

Lateral restraints were provided by greased steel beams, allowing vertical movement of the sheets only.

-31 For Series 1 and 2 tests and Series 3 a rigid beam the width of the specimen was placed centrally across the specimen. For series the beam was 2/3 the width of the specimen. A load was applied centrally through the beam with load vs. central deflection recorded.

TABLE 8 SINGLE SHEET (SERIES 1) Load kN Average Centre Deflection Average End Dellection (mm) (mm) 0.00 0.00 0.00 0.00 1.36 0.20 5.90 3.49 0.43 7.40 4.09 0.49 10.00 4.98 0.56 13.50 5.16 0.84 16.20 7.16 0.71 18.30 7.90 0.74 20.20 8.55 0.78 22.10 9.17 0.82 23.50 9.73 0.84 25.40 10.45 0.88 27.30 11.11 0.91 28.40 11.95 0.95 31.90 12.91 0.99 34.40 13.85 1.03 37.50 15.12 1.08 41.10 16.74 1.13 44.30 18.15 1.18 47.90 19.77 1.24 50.50 21.01 1.29 24.80 23.05 1.38 57.10 24.32 1.41 60.80 26.21 1.48 65.80 28.01 1.53 65.00 29.92 1.57 -32- Load kN Average Centre Deflection Average End Deflection (mm) (mm) 68.50 31.54 1.60 70.20 38.13 1.63 71.00 34.47 1.65 71.20 35.50 1.66 71.00 36.21 1.66 Clear span 2850mm Width 815mm Thickness 2mm Dead loads to be added to the above: 124kg bems 265kg Sand TABLE 9 DOUBLE SHEET (SERIES 2) Load (kN) Average Centre Average End Load (kN) Average Centre Average End Deflection (mm) Deflection Deflection (mm) Deflection (mm) (mm) 0.00 0.00 0.00 66.27 21.07 2.73 0.00 0.76 0.22 67.79 21.65 2.77 0.00 0.94 0.27 68.29 22.13 2.81 2.17 1.70 0.44 70.28 22.59 2.84 4.17 2.37 0.59 72.17 23.20 2.88 5.93 2.99 0.76 73.17 23.68 2.91 7.91 3.58 0.84 74.89 24.32 2.94 10.28 4.26 0.97 75.92 24.91 2.97 12.12 4.82 1.05 77.32 25.58 3.01 13.79 5.30 1.13 48.55 26.22 3.04 16.04 6.04 1.23 80.82 27.06 3.08 18.08 6.51 1.30 82.24 27.64 3.12 19.74 7.04 1.37 83.88 28.38 3.15 22.00 7.58 1.44 85.13 29.02 3.16 24.31 8.20 1.52 88.12 30.30 3.24 26.13 8.64 1.57 89.60 30.89 3.26 28.31 9.26 1.64 90.09 31.35 3.29 29.83 9.78 1.69 91.53 32.19 3.32 31.66 10.33 1.75 92.50 32.71 3.33 33.81 10.90 1.81 93.15 33.20 3.35 36.07 11.56 1.57 94.89 34.26 3.38 -33- Load (kN) Average Centre Average End Load (kN) Average Centre Average End Deflection (mm) Deflection Deflection (mm) Deflection (mm) (mm) 38.18 12.02 1.93 96.05 34.75 3.39 40.14 13.63 1.98 96.22 35.51 3.41 42.05 13.13 2.03 95.47 36.00 3.42 43.93 13.71 2.07 97.39 36.86 3.42 46.58 14.47 2.14 97.83 37.50 3.43 48.28 14.91 2.27 98.00 38.15 3.43 49.82 15.51 2.30 96.98 38.53 3.44 52.80 16.22 2.36 97.21 40.47 3.26 54.33 16.77 2.39 99.01 42.14 3.28 56.79 17.66 2.47 99.28 43.24 3.29 58.33 18.11 2.50 100.60 44.32 3.30 59.78 18.68 2.54 101.13 45.34 3.31 61.14 19.21 2.59 102.45 46.71 3.31 62.88 19.78 2.63 106.99 51.34 3.32 63.33 20.01 2.67 103.44 54.90 3.32 64.97 20.49 2.70 Clear span 2850mm Width 960mm Thickness 3mm Dead Loads to be added to the above: 64kg beams 278kg Sand TABLE TRIPLE SHEET (SERIES 3(1)) Load (kN) Average Centre Average End Load (kN) Average Centre Average End Deflection (mm) Deflection Deflection (mm) Deflection (mm) (mm) 0.00 0.00 0.00 3.42 3.56 1.87 0.00 1.07 1.30 25.88 8.25 2.05 1.95 1.46 1.47 49.80 11.04 2.24 3.91 1.81 1.54 75.88 16.16 2.62 5.86 2.54 1.58 101.32 20.41 2.61 8.06 2.83 1.60 112.79 22.61 2.69 10.01 2.98 1.44 114.99 23.05 2.70 11.72 3.52 1.52 117.19 23.63 2.71 14.40 3.76 1.57 119.38 24.07 2.72 20.02 4.39 1.67 121.58 24.17 2.73 -34- Load (kN) Average Centre Average End Load (kN) Average Centre Average End Deflection (mm) Deflection Deflection (mm) Deflection (mm) (mm) 24.17 5.13 1.85 125.73 25.78 2.82 28.08 6.30 1.75 126.22 26.12 2.84 32.23 7.52 1.97 128.66 26.86 2.88 36.38 8.20 2.07 129.88 26.93 2.89 41.53 8.59 2.11 133.30 27.25 2.91 45.65 8.88 2.11 134.03 27.44 2.87 50.05 9.42 2.26 135.01 27.54 2.85 55.18 10.25 2.18 138.18 29.79 2.89 60.30 10.69 2.38 140.63 31.01 2.97 65.67 11.82 2.23 143.07 32.37 2.91 70.56 12.99 2.48 145.51 33.30 3.12 76.17 13.92 2.41 147.46 35.25 3.13 81.54 15.19 2.54 148.93 37.79 3.14 86.67 16.06 2.45 150.15 42.24 3.09 92.04 17.24 2.68 149.41 44.63 3.12 97.41 18.26 2.63 148.68 46.19 3.13 102.54 19.58 2.59 147.71 47.9 3.10 107.67 20.21 2.60 138.18 48.93 3.07 *127.55 22.31 2.67 Load removed to adjust sand Clear span 2850mm Width 2260mm Thickness 3mm Dead loads to be added to the above: 79kg beams 416kg Sand TABLE 11 TRIPLE SHEET (SERIES 3(2)) Load (kN) Average Centre Average End Load (kN) Average Centre Average End Deflection (mm) Deflection Deflection (mm) Deflection (mm) (mm) 0.00 0.00 0.00 120.69 17.15 3.14 0.00 0.95 1.10 125.60 18.00 3.19 0.49 1.05 1.11 130.55 18.80 3.24 1.07 1.09 1.11 135.88 19.66 3.29 5.14 1.82 1.21 140.69 20.64 3.33 10.30 2.62 1.39 145.28 21.47 3.38 Load (kN) Average Centre Average End Load (kN) Average Centre Average End Deflection (mm) Deflection Deflection (mm) Deflection (mm) (mm) 15.36 3.43 1.54 150.53 22.42 3.43 20.24 4.04 1.68 155.56 23.57 3.47 25.23 4.76 1.82 159.45 24.47 3.51 30.40 5.45 1.95 *167.31 26.13 3.58 35.54 6.16 2.07 0.00 4.36 1.47 41.06 6.83 2.18 180.80 26.84 3.58 45.71 7.26 2.28 167.52 28.03 3.73 50.61 7.75 2.35 171.37 26.85 3.76 55.36 8.24 2.43 175.41 29.77 3.79 60.76 8.91 2.50 178.48 30.54 3.81 65.84 9.50 2.56 180.98 31.12 3.83 70.47 10.12 2.63 183.41 31.72 3.85 75.87 10.78 2.68 187.22 32.73 3.88 80.27 11.40 2.74 190.00 33.52 3.90 85.59 12.07 2.80 193.22 34.36 3.92 90.22 12.72 2.84 195.65 35.15 3.93 95.37 13.44 2.89 200.41 26.99 3.96 100.33 14.09 2.94 202.89 38.33 3.98 105.29 18.83 3.00 204.34 39.53 4.00 109.63 15.44 3.03 202.04 42.60 3.98 115.50 16.40 3.09 195.58 46.73 3.89 Load removed to adjust sand Clear span 2850mm Width 2260mm Thickness 3mm Dead Loads to be added to the above: 163kg beams 410kg Sand Graphical representations of the load vs deflection data for tables 8 to 11 are shown in FIGS 16-19.

CONCLUSIONS

Ultimate Moment Capacity of Sheet Piling System Three series of tests were conducted on the sheet piling systems shown in FIG 15. Four panels with simply supported end conditions and a span of 2850 mm were tested to failure under transverse line loads at midspan. Series 1 had a single panel sheet piling system whereas Series 2 and 3 had a "double panel" and a triple panel sheet panel -36system, respectively. In Series 3, two tests were conducted with different lengths of midspan line loads (2250 and 1500 mm). These test results are further evaluated and compared with corresponding theoretical predictions.

1. Tensile Testing of Steel Specimens Tensile testing of steel specimens cut from sheet piling gave the following average tensile strength properties: Yield stress fy 409 MPa* Ultimate tensile stress f, 501 Mpa based on 0.2% proof stress Tensile test results showed that the steel used in the sheet piles had tensile stress-strain curves with a substantial yield plateau, an average percentage elongation at failure of 29.1%, and f./fy ratio of 1.22. These results indicate that the steel used has adequate ductility.

2. Transverse Load Tests on Sheet Piling Systems In all three test series, test panels appeared to have developed plastic hinges at midspan at ultimate failure loads without any local buckling prior to this. Theoretical moment capacity calculations using measured panel geometry and yield stress also support this observation. In the absence of local buckling, the ultimate moment capacity has been taken as the product of steel yield stress fy and the plastic section modulus of the panel S. The measured yield stress used in the theoretical calculations is 409 Mpa whereas the important measuwed panel dimensions used are: Thickness 2.995 mm Rib Height 145 mm Pitch 332 mm For each test series, experimental ultimate moment capacity of the sheet piling system is calculated based on the maximum applied test loads, and compared with the corresponding theoretical predictions.

-37- Series 1: Single panel sheet piling system For this series, the theoretical moment capacity was calculated using both an exact panel geometry that included the effects of curved comers (Case 1) and an approximate panel geometry that ignored them (Case 2).

Theoretical ultimate moment capacity 54.2 kNm (Case 1) and 50.4 (Case 2) Experimental ultimate moment capacity 53.3 kNm As seen above, theoretical and experimental capacities agree very well.

Series 2: "Double" panel sheet piling system For this series, the theoretical moment capacity was calculated using only the approximate panel geometry that ignored the effects of curved comers (Case 2) as the effect on moment capacity was small.

Theoretical ultimate moment capacity 81.1 kNm (Case 2) Experimental ultimate moment capacity 78.6 kNm As seen above, theoretical and experimental capacities agree reasonably well.

Series 3: Triple panel sheet piling system Test Series 3(1) was not considered in this report as it had a reduced loading width. For the other test, Series 3 the theoretical moment capacity was considered to be three times that of a single panel system (Series 1).

Theoretical ultimate moment capacity 162.6 kNm (Case 1) and 151.2 kNm (Case 2).

Experimental ultimate moment capacity 149.6 kNm.

As seen above, theoretical and experimental capacities agree reasonably well difference compared with Case 1).

Experimental ultimate moment capacities in Series 2 and 3 appear to be -38slightly less than the corresponding theoretical moment capacities. Therefore, the following recommendations are made based on the test results and theoretical predictions and associated assumptions as stated in this report.

1. Ultimate moment capacity of a single sheet piling system can be taken as 50 kNm.

2. Ultimate moment capacity of a triple sheet piling system can therefore be taken as approximately three times that of a single sheet piling system, ie. 150 kNm.

3. Ultimate moment capacity of a "double panel" sheet piling system can be taken as 78 kNm.

It will be clear to a skilled addressee that with the many aspects of the invention described herein, various combinations of features from these aspects can be employed rather than the specific methods and systems which are described by way of example only.

For example, FIG 20 shows a cross sectional view of a sheet piling wall 200 supporting an earth mass 201 in an excavation.

The sheet piling wall 200 comprises, typically, a 3mm thick corrugated steel sheet having the same type of configuration as that shown at 61 in FIG 8 and is by earth anchors 202.

To stiffen the upper region of the sheet piling barrier, a ring beam construction is formed by supporting 450-500mm wide strip of F62 mesh 203 against the speed outstanding ribs and securing the mesh thereto by welding spaced Y-16 bars 205 to the sheet piling where the bars 204 come into contact with the vertical ribs 203.

A 450mm wide waler 206 formed of 3mm steel and having a cross section similar to the sheet piling is secured transversely across the top of the sheet piling 200, the mesh 202 and reinforcing bars 204 by bolts 207 extending through the orthogonally oriented sheets where respective ribs contact each other.

Concrete 208 having a strength of about 32 in Pa is introduced into the space between the orthogonally oriented sheets to form a continuous ring beam about the top of -39the sheet piling wall 200.

Throughout this specification and claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or group of integers or steps but not the exclusion of any other integer or group of integers.

Claims (3)

1. 2. A sheet piling member according to claim 1 wherein the contoured member is formed from 3mm steel.
2. 3. A sheet piling member according to either claims 1 or claim 2 wherein the steel is block mild steel.
3. 4. A method of forming a sheet piling member comprising the step of roll forming a contoured member from a steel sheet wherein said sheet piling member comprises the contoured member. Use of a roll formed sheet piling member substantially as hereinabove described with reference to the drawings and/or examples.