CONSTRUCTION DESIGN SHARE COMPANY

1. INTRODUCTION
1.1 General
Following an agreement signed on 21
st
of April 2011 between
Matahara Sugar Factory and Construction Design Share Company
(CDSCo), Geotechnical works Business Unit of the Company has
performed geotechnical investigation works at Sabure, Afar for the
New Sugar Factory Project.
The investigation comprises of core drilling, pitting, insitu testing,
sampling and laboratory testing.
1.2 Location
The project site is located in Sabure, Afar Regional State, locally
known as Dankar, which is some 70km from Matahara town, which in
turn is at 200km from Addis Ababa along the road to Djibouti.

Location of the test points and layout plan of the project site is
attached.
2. METHODOLOGY OF INVESTIGATION
To get reliable and sufficient information about the surface and
subsurface geology and hydrogeology of the project area, the following
methodology was employed:
Planning of office and field work,
Rotary core drilling with in situ testing
Test pit excavation,
Sampling,
Logging,
Conducting different laboratory tests and technical report writing.
2.1 Drilling and Pitting
The drilling operation was carried out using two mounted Koken
/Trailer rigs and a BR50 drilling machine.
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The methods applied in the investigation were in compliance with the
code, specification and standards of the American Society for Testing
Materials /ASTM/.
Plate. 1, 2 Trailer Mounted Koken Drilling Rigs
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A continuous rotary core drilling technique was used in order to obtain
high quality cores. During drilling, complete geological materials
reflecting the boreholes sections were collected as precisely as possible.
In loose and compacted soils, a dry drilling technique was used
starting with 116mm and reducing (when necessary) to 75mm
diameter with tungsten carbide bits fitted to a single core barrel.
As soon as soil or rock cores are removed from core barrels in each run,
they were placed in standard partitioned wooden core boxes and
described immediately on site. Finally, the boxes are properly labeled,
photographed and transported to the store.
For the purpose of visual inspection and completeness of data
numerous test pits were excavated distributed within the factorys
structures, inspected, logged and backfilled. Moreover, additional test
pits were excavated at the proposed road alignment of the factory and
samples were recovered for modified proctor density and tests.
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Plate 3, 4 Test Pits
2.2 Standard Penetration Test (SPT)
This test is performed to evaluate the degree of in site compactness
and/or consistency and strength of soils.
During drilling operation, at the bottom of the hole of required depth,
the split spoon sampler is lowered and driven in to the formation by a
drop of hammer of 63.5kg mass falling vertically through a height of
76cm. The method measures the resistance to penetration offered by
the formation. It is measured on the basis of the number of blows of
hammer required for a sampler tube penetration of 45cm. The number
of blows counted for the last two intervals, 15cm each, is added to
report as N-value of the test discarding the first 15cm penetration.
2.3 Sampling and Testing
Desired undisturbed soil samples were collected, where favorable
geological layers are encountered at depths shown on the log sheet of
each bore hole and sealed with wax in order to preserve the natural
moisture content and transported to the main soil laboratory of
CDSCo. in order to perform the required tests.
3. GEOLOGY AND SEISMICITY
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3.1 Regional Geology
Since the area is located within the main Ethiopian Rift valley its
regional geology is highly affected by volcanism, tectonics, erosion, and
deposition.
3.2 Seismicity
The methods of assessing likely earthquake intensity and frequency at
a given site are complex, requiring reasonable judgment and collection
of geological and seismic data.
Due to this complexity for the structures with lesser magnitude, the
tendency is to rely upon seismic risk maps. The maps are often
published in national or state building codes, which recommend the
engineering precaution to be taken in each rank of hazard in the map.
Ethiopia is divided into zones of approximately equal seismic risks
based on the known distribution of past earthquakes. By definition,
the hazard with in each zone can be assumed to be constant. (Refer
Table 1 below). From the seismic hazard map of Ethiopia, the project
site falls under zone 4 which corresponds to maximum hazard. This
map is based on the amplitudes to be expected during 100 years return
period.
The parameter
o
, the ratio of the bedrock acceleration to the
acceleration of gravity depends on the seismic zone (see the table
below)
Table1. Bedrock acceleration ratio
o
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Zone 4 3 2 1

o
0.10 0.07 0.05 0.03
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Figure 2: Seismic hazard map of Ethiopia
Project location
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3. 3 Topography, Local Geology

3.3.1 Topography
The area and its surroundings have flat topography. Currently it is further
modified and leveled as preparation for construction. No hills are observed in
close range to the site. A river called Kebena is located near the site.
3.1.2 Local Geology
Surfacially the area is covered uniformly by grayish color silty soil. In order
to establish subsurface geology and groundwater condition of the site 38
boreholes and 18 test pits (distributed within the different structures or
blocks of the factory) were proposed by the client. Progressive observation
and characterization was made in the course of drilling and it was agreed
that since the site is constituted by uniform formations some boreholes were
omitted. The formations were characterized according to samples recovered
by drilling and visual inspection of the test pits. Detailed outcome of the
drilling is presented on the log sheets while summary of the encountered
units is presented below.
A. Grayish Silty SAND
This unit is encountered in all the boreholes. It covers the surface of the site
as well as the top 5.50 to 7.0m. It is medium dense to dense, grayish, silty
SAND/ sandy silt with occasional gravels. Standard Penetration Test
conducted on this layer gave an N-value in the range of 11 to 24. This unit
appears loose when observed from core recovered by drilling but when
observed in the test pits the walls are intact and not easy to excavate using
pick axe and shovel. This is further supported by the high N values.
Occasionally this unit comprises high percentage of gravels and rock
fragments, as can be observed in boreholes K33, K32, and K34.
The following averaged design engineering parameters are considered to
represent the layer:-
Bulk Unit Weight = 14.4KN/m3
Specific Gravity = 2.49
Moisture Content = 10.3%
Cohesion Value = 18.8KN/m2
Angle of internal friction = 25.70
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Free Swell = 10%
Plasticity Index = 11.5%
B. River GRAVELS and SANDS
This unit is encountered underlying the top sandy silt/ silty sand soil. It is a
granular material composed of rounded, smooth river gravels and pebbles
mixed with sand. Occasionally pure river sand becomes dominant. Sometimes
this unit is intercalated by thin layer of silty formation. Standard Penetration
Test conducted on this layer gave varying N values in the range 23 to
refusals.
C. Sandy SILT
This unit occupies the bottom part of all of the boreholes. It underlies either
the top silty sand soil or the river sand and gravels. It is firm, brownish (wet)
and grey (dry) sandy SILT with some clay. Occasionally this unit is
intercalated by lamina of sand dominated formation. Groundwater is
encountered on this formation; as a result part of this formation which lies
below the water level is more cohesive than the part which lies above.
Standard Penetration Test conducted on this layer gave an N value in the
range of 11 to 43 with the most part being in the range of 14 to 19.
The following averaged design engineering parameters are considered to
represent the layer:-
Bulk Unit Weight = 15.7KN/m3
Specific Gravity = 2.5
Moisture Content = 9.1%
Cohesion Value = 8.4KN/m2
Angle of internal friction = 27.40
Free Swell = 12.3%
Plasticity Index = 6.3%
3.3.3 Ground Water Condition
Groundwater was encountered during drilling at depths in the range of 13.50
to 14.50m.
The following averaged engineering parameters are considered to represent
the water:-
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Chloride Content = 116.5mg/c
Sulphate Content = 77.7mg/c
PH-Value = 6.9
4. FOUNDATION RECOMMENDATION
4.1General
The geology of the site is uniform and it is composed of loose to medium dense
silty sand with occasional gravels followed by a relatively thin layer of
rounded gravels and pebbles and firm moist sandy silt soil is encountered to
the end of the drilling.
In some borehole log sheet the rounded gravel sand pepples will disappear
and pure, loose to medium dense sand will be found below the top soil layer.
In general the country has been divided in accordance with figure 2 (from the
geological report) and table 1 in to seismic zones, depending on the local
hazard .The site is located at the highly seismic area and seismic hazard
shall be taken in to consideration in the design of the structures.
4.2 Bearing Capacity Calculation
Bearing capacity computation is made using different calculation methods
giving stress to field tests. Site inspection results with engineering
considerations are taken to give the foundation recommendations.
Meyerhof approach is used for computing the allowable bearing capacity.
This approach is calculated for 25-mm settlement using SPTvalues
(Standard Penetration Test values) as can be seen below.
Q
all
= N x Kd B F
4
F
1
Q
all
= N (B+F
3
)
2
Kd B>F
4
F
2
B
2
Where: - Kd = 1 +.33(D/B) 1.33
N = Adjusted SPT blow count
B = Width of foundation
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D = Depth of foundation
So = Allowable settlement
For So=25mm
N70
F1 0.04
F2 0.06
F3 0.3
F4 1.2
Adjusted N- Value calculation
Adjusted N value = N-count x Cn x 1x 2 x 3x 4
Where: - Cn = Adjustment for effective overburden pressure
1 = Adjustment for hammer energy
2 = Adjustment for rod length
3 = Adjustment for liner
4 = Adjustment for borehole diameter
In these equations N is the statistical average value for the footing influence
zone of about 0.5B above footing base to at least 2B below.
Note:-In these equations, footing width is a significant parameter. Obviously
if the influence depth is on the order of 2B a larger footing width will affect
the soil to a greater depth and strains integrated over a greater depth will
produce a larger settlement.
Considering the allowable settlement to be 25mm at the recommended
foundation depth the following allowable bearing capacity is calculated for
the following structures.
No. Type of Structure Foundation Type Foundation Depth
from N!
"earin#
Capacity
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1 Cane Handling Isolated Footing 3.0m 220Kpa
2 Boiler House
2.1.For the Building Isolated Footing 3.0m 200Kpa
2.2.For the Tanks Mat oundation 3.0m 2!0Kpa
3 Po"er #u$%#tation Mat oundation 2.&m 3&0Kpa
' Milling House Mat oundation 2.&m 3&0Kpa
& Centriugal House Isolated Footing 3.0m 220Kpa
( #ugar #tore Isolated Footing 3.&m 1)0Kpa
* +orkshop Isolated Footing 2.&m 200Kpa
! Pro,ess House Mat oundation 2.&m 300Kpa
) Pump House Mat oundation 3.0m 300Kpa
10 -iuser Isolated Footing 2.0m 1)0Kpa
Additional Consideration
PH, Chloride and Sulphate content of soil was determined according to BS
1377, and all values are with in the permissible requirement (BS 3148).
Therefore Ordinary Portland Cement can be used for the structures.
4.3 DESIGN CONSIDERATION FOR THE ROAD
Engineering characteristics of sub grade soil, i.e. its CBR strength is used to
design foundation of heavy duty pavements. It is clear that heavy trucks are
expected to move around the service area within the premises of the factory
for loading and unloading purposes. Considering this fact sub grade soil
investigation has been conducted using test pits along with sampling and
subsequent libratory testing.
The entire site is composed of uniform geology as revealed by borings and pit
excavation. For this particular case associated with road base, test pits
TP19, 20, 21 and 22 have been dug to a maximum depth of 4m. The test pits
were properly logged and representative samples were taken for laboratory
testing form layers that are likely to be affected by traffic load.
The laboratory tests conducted on the sub grade soil samples are
CBR test
Classification test (Atterberg limits and grading)
Natural moisture content.
The summary of the soil test results are appended in the report.
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4.3.1. LABORATORY TEST RESULTS AND ANALYSIS
The test pit logs depict that there exist two layers which are sandy silt soils.
The most problematic in sub grades are expansive soils which does not exist
at this site makes the situation very favorable for the desired purpose.
4.3.1.1. Laboratory CBR
Laboratory CBR indirectly measures the shearing resistance of a soil under
controlled moisture and density conditions. Therefore, Laboratory CBR tests
were under taken on the sub grade soil samples to measure its strength. The
CBR values are reasonably high enough which falls in the range of 9% -18%
with one exceptional result of 3%.
4.3.1.2. Plastic Index
The Plasticity of a soil gives very good indication of its expansion potential.
Therefore, Atterberg limit tests were undertaken to asses its expansion
potential and the results reveal that the soil is low plastic. Besides the swell
test result also depicts that it is very far below the permissible limit which is
4%.
4.3.1.3. AASHTO Soil Classification
After conducting Atterbergs limit and gradation tests it is possible to classify
sub grade soil as per AASHTO soil classification. In general, using AASHTO
soil classification a material can be rated as excellent to poor as road sub
grade material. Accordingly, the sub grade soil of the site in consideration
falls dominantly in A-5 class and rated as fair to good as per AASHTO road
sub grade rating.
New Sugar Factory Geotechnical Investigation Report