Diaphragm Wall Method Statement

DIAPHRAGM WALL PRESENTATION
Present by
Diaphragm Wall
Sho
Diaphragm Wall Construction
Functions:
• Temporary and / or permanent structures

• Resist lateral forces
– Transferred from ground, water, earthquakes & etc.
• Load bearing elements as foundation
– To resist vertical forces
Major Operations in Diaphragm Wall Construction:
• Guide Wall Installation

• Drilling Fluid (Stabilizing Solution) Preparation
• Excavation Our Focus
• Stop End Installation
• Reinforcing Steel Cage Installation
• Concreting
1. Guide Wall Installation
1.1 Guide Wall Structure

• Guide wall installation is the first step of diaphragm wall construction
• Important to determine continuous wall edge and elevation accuracy
• Maintain soil stability (wall collapse prevention) during excavation
General Specification
• Excavation
width + 50mm
width: wall
• Rib thickness:
200mm
• Top thickness:
1000-1050mm
• Height: 1700-2000m
– Overall height depending on soil condition
– Top of guide wall is 1.5m above ground water table)
• 1:3 mortar slab thickness (improve bearing): 70mm


Design Criteria
• Deviation at center line: +/- 10mm
• Inner wall verticality: < 0.5%
• Excavation width: +/- 10mm
• Top surface flatness: +/- 10mm
Design Criteria
• Withstand the construction loads

• No leakage of drilling fluid or concrete
• Top of wall must >100 mm higher than adjacent ground to prevent
surface water entering into trench and contaminating drilling mud or
concrete (similar to a curb)

1.2 Guide Wall Extension

• Method to ensure turns or corners being fully excavated
• Achieving the minimum excavation
• For rock penetration, the extension provides room for chisel, core-
barrel or down-the-hole hammer placement
1.3 Construction Sequence

1. Surveying
• Stake out reference points and markers that guide the construction of
new guide wall
2. Excavation
• Use excavator for initial

excavation
• Fine tone by hands

3. Formwork & Reinforcement
• Use base formwork to position the guide wall
• Rebars are positioned within formwork before concrete is poured in
• Outer wall of guide walls use adjacent earth as formwork
• Steel formwork is setup for inner wall

4. Place Concrete
• Properly place concrete using a concrete vibrator to
consolidate the concrete mixture
– prevent air bubbles and other curing issues
• Add lateral support
5. Remove Formwork & Add Lateral Support

• Remove formwork upon concrete reaching suitable strength
• Add lateral support for the final structure
– every 2m spacing with strut at 1.2m vertical distance above guide wall
bottom
• Before the concrete reaching 70% of design strength, heavy
equipment must not move near the guide wall



6. Backfill
• Backfilling highly adhesive soil into guide wall immediately
• Compact the backfill
7. Joint Construction
• Joints are rough chiseled
• Add joint rebars to improve shear resistant
1.4 Precast Guide Wall
• Used by a Turkish contractor

2. Drilling Fluid (Stabilizing Solution) Preparation
2.1 Why Needs Drilling Fluid?
• Prevention of wall collapse

• Prevention of ground water from leaking into trench
• Withstanding earth pressure
• Stabilization of excavated trench for a prolonged period
• Prevention of sedimentation
2.2 What Is Drilling Fluid?
• The simplest drilling fluid can be prepared by mixing bentonite into

water
• Traditional Method (Bentonite + Water + Additive):
Bentonite
• General dosage: 5% - 8% of total mixture depending on soil condition
• Bentonite will settle if concentration is too low
• Excellent colloidal property (thixotrophic gel viscosity)
• Expand when wet
Water
• Preferable city water with minimum impurity
CMC (Sodium Carboxy Methyl cellose)
• Synthetic starchy white powder
• increase viscosity
• General performance: 1% of total mixture can increase
viscosity by 150 cp
Dispersant (so-called mud thiner)

• lower viscosity
• Prevention of gelatinization of solution due to present of
cement
FCL (Sodium ferrochrome lignin-sulfonate)

• black powder
• General dosage: 0.1-0.3%
Sodium Nitrofuminate
• Dark brown powder
• General dosage: 0.1-0.3%
Newer Method (Polymer + Water):
Polymer
• Engineering substance to replace bentonite
• Inhibiting swelling action on clay
• Avoid undesirable viscosity increase
• Avoid fine solid dispersion in fluid
2.3 Mechanism of Drilling Fluid

Criteria
• The water level of drilling fluid must be at least 1m higher than ground water table
– Generate higher head pressure to withstand earth pressure and ground water entering
into wall
• The specific gravity of drilling fluid must be > 1 (water)
• The viscosity of drilling fluid must be suitable to form thin and strong film adhering
on the surface of wall
Process
• The mud film is formed through filtration
– The action that the drilling fluid is constantly permeating into soil direction due to
greater head pressure
• It is influenced by permeability of soil
– Clay Seam: ~0
– Silt Seam: High
– Sand Seam: Higher
– Sand with Gravel: Highest -> lead to thickest film
• As permeating into soil, drilling fluid enters in the gap of soil grain.
• The particles of bentonite separate from water and stay inside the grain
• After forming a protective film, further ingress of water is stopped
2.4 Relation Between Density and Properties of

Solution
2.5 Methods for Adjusting Drilling Fluid

• When viscosity is low
– Add 0.05 - 0.2% CMC

• When viscosity is high
– First to add water to dilute

– Add 0.05 - 0.3% mud thinner
• High filtration in gravel layer (nearly 10cc)
– Increase bentonite mixing ratio

– Add CMC
• Poor stability against gravity (excavated trench left long time)
– Increase bentonite mixing ratio

– Add CMC
2.6 Quality of Drilling Fluid

Strong film
• Thin film
• High density
• Resistible against impact
• Prevent permeation of ground water
Poor film
• Thick film
• Weak because bentonite only accumulated on the surface, not within
soil grain
2.7 Case Study of Shenzhen Metro Project

(Specification, Testing Standard & Tank
Requirements
Formula for sand, sandy clay & highly weathered sand stone
• Bentonite: 70 kg (6.5%)
• FCL: 1.8 kg (0.17%)
• City Water: 1000 kg (93.26%)
• CMC: 0.8 (0.07%)
• Drilling fluid specification

2.8 Storage Tank

• Storage tank arrangement:
Storage tank photos:

• Storage tank sizing:

2.8 Drilling Fluid Treatment Equipment

• Mixer
• Manual Mixing Type
– Equip with high speed agitator
– Standard tank capacity 1,000 - 2,000L
High-speed Automatic Mixer

• Computerized PCL control
• Automatic bentonite or polymer dispensing
• 4000 - 4500L capacity
2.9 Desander
• Equip with 1 - 2 layers of various sized vibrating mud screen
• For debris and gravel removal
• Equip with 1 - 2 cyclone
• For sand separation
• Recommended capacity for diaphragm wall construction:
– 150 - 250 cbm / hour (Grab method)
– 500 cbm / hour (Hydro-mill method)
• Example of 1500 cbm/hr desanding and

storage plant
2.10 Filter Press

• Convert liquid drilling solution to semi-solid form
• Environmental friendly method for bentonite disposal
• Produce 30-40% water content mud cake
• Separated water is safe to dispose
• Portable filter press for U.S.A market

3. Excavation
3.1 Excavation Process

Soil Layer
• Standard panel width: 5.6 - 6m
• Standard grab shovel jaw length: 2.8m
• Standard grab shovel jaw width:
120cm,150cm
60cm, 80cm, 100cm,
• Require 3 bites down to final depth per panel

• Excavation sequence - first excavating two sides of panel, then lastly
the middle of panel
3. Excavation
3. Excavation
• Need to flatten the bottom of trench, then clean

the trench with new drilling fluid
• After one panel (6m wide wall – Primary Panel) is
completed, the grab should excavate the second
panel next in line, then revisit and excavated the
skipped one (Secondary Panel).
• Verticality Accuracy: < 1 / 300 [Depth / Deviation]
• Standard types of equipment:
– Hydro mills
– Hydraulic cable grab
– Fully-guided (kelly) / Semi-guided grab
– Mechanical cable grab
3. Excavation
3. Excavation
Completely Decomposed Rock layer

Hydro mill method
• by continuously cutting into completely decomposed rock layer
(ex.CDG)
Hydraulic grab method

• Drill side guide holes till the final depth
• Through guide holes, the hydraulic grab can shear the rock layer with
high jaw closing force
Mechanical grab method
• Penetrate by impaction
3. Excavation
Fresh Rock
Pre-drill & Chiseling
• Drill side and middle guide holes till the final depth
– Down-the-hole hammer (productivity: 2.5 - 3m/hr)
– Rotary drill rig with core-barrel (productivity: 0.5 - 0.7m/hr)
• Use rectangular chisel to break rock in between the two guide holes, guide
holes can improve the chiseling accuracy
• Impact area: 80×120cm
• Chisel weight: approximately 11 ton
• Impact distance: within 1.5m to reduce deviation and vibration

• Use grab to remove rock debris at trench bottom
3. Excavation
3.2 Collapse Prevention During Excavation

• Soft ground and thick sandy layer can be problematic
• Measure to reduce chance of wall collapse:
– Reduce ground pressure
• Load > 20kN/m2 near wall
• Vehicles must be 3.5m away from wall
– Steady grab motion
• Avoid aggressive movement
• Use good quality drilling solution
– Good grade of Bentonite
• Use CMC to ensure suitable viscosity
• Ensure sufficient density
• Drilling solution level must be at least 1m higher than ground water level
– Pour concrete within 24 hours
– Use jet grout to stabilize weak soil
– In case of collapse, backfill immediately and apply jet grout into the wall and surrounding
soil
– Ensure good quality of trench
• Verticality (> 0.5%)
• Wall depth within tolerance (+100mm <--> -200mm)
• Wall width within tolerance (0 <--> +50m)
4. Stop End & Water Stop
4.1 Typical Panel Arrangement

4.2 Conventional Stop End – Type 1

Vertical Connection
Conventional Stop End – Type 2

Horizontal Connection Water Stop Installation
Conventional Stop End – Type 2

Casing Stop End Casing Jack
5. Other Methods
5.1 Contact Grout
• Carry out for

Loading Panel
Only
• Drill through
reservation tube to
depth of 1m below
toe of wall
• Carry out Contact
Grout to provide
good contact
between wall and
bedrock
5. Other Methods
5.2 Shear Pin
• Hard rock can be

encountered at
shallower depth
• Due to difficulties of
excavation into rock,
a shear pin is
adopted as an
extension of
diaphragm wall into
bedrock enhance the
toe stability of wall
6. Measure
6.1 Monitoring of Wall (Alert / Alarm / Action Level)

6. Measure
6.2 Measure before placing concrete

Wall Bottom Residue Thickness Verticality
In Process Verticality Report

6. Measure
6.3 Measure after placing concrete

• Detect concrete defects
– Honeycomb formation due to inadequate vibration
– Segregation due to over vibration
• Improper concrete placement method
• Wash out of cement, cracks in the wall
7. Grab Comparison
7.1 Mechanical Cable Grab

Advantages:
• Simple
• No hydraulic components on grab
• Free fall winch
• Very deep excavation
Disadvantages:
• Closing force based on weight and wire part lines
• More part lines decrease the closing speed
• Heavy grab requires high line pull crane. ex Liebherr / other European cranes.
• High machine price and maintenance cost
• Require high skilled operator for vertically control because of no monitoring.
• Require frequent manual measure with instrument
• High fuel consumption of crane - big engine
• Require free fall to achieve productivity meaning high maintenance on grab
body
• Require manual grab swivel for balance excavation
7. Grab Comparison
7.2 Kelly Grab

Advantages:
• High verticality for shallow excavation
• Hydraulic controlled grab swivel for balance excavation
• Can use existing drilling rig for grab conversion
• High closing force
• Require less skillful operator than mechanical grab
• Lower fuel consumption
Disadvantages:
• Shallow excavation, less than 30m
• Light grab body weight (~7 ton), not suitable for hard ground
• Work radius is constrained by mast displacement, need to work very close
to trench
• If crawlers accidentally move during excavation, the kelly can be damaged
• More steps for changeover compared to mechanical grab
7. Grab Comparison
7.3 Semi-Detachable Kelly Grab

Advantages:
• High verticality for initial excavation
• Can use existing drilling rig for grab conversion
• High closing force
• Improvement to kelly grab for deeper excavation ~40m
Disadvantages:
• No verticality control after reaching kelly bar section (~30m)
• Light grab body weight (~7 ton), not suitable for hard ground
• Work radius is constrained by mast displacement, need to work very close
to trench
• If crawlers accidentally move during excavation, the kelly can be damaged
7. Grab Comparison
7.4 Hydraulic Cable Grab

Advantages:
• Heavy grab weight (up to 31.5 ton)
• High accuracy in verticality throughout the whole excavation process,
controlled by flaps and make measurement on the go
• Very deep excavation with high accuracy
• Large working radius to minimize the chance of wall collapse
• High closing force (160 ton)
• Can use two winches for high speed hoisting and lowering
• High line pull
• Less maintenance due to not require free fall
Disadvantages:
• Specialized machine but cannot use for other purposes
8. Fuel Consumption & Performance
Average Recorded Field Data

8. JINTAI Hydraulic Grab Features
8.1 Heavier Grab Weight & High

Single Line Pull
• SG46 and SG60 are deploying two synchronized
winches for grab hoisting and lowering operation.
Double Winches
• The single line pull output is far more powerful than
conventional high line-pull foundation crane like
Liebherr.
• For this reason, our machine can equip much
heavier grab to improve stability, verticality and
penetration in hard ground condition.
SG60 SG46 Mechanical Grab

Single line pull 600 kN 460 kN Based on the
carrying crane,
usually 300 kN
Max. Grab Weight 31.5 ton 23 ton Approx. 15.5 ton
8.2 Powerful Closing Force

• Deliver powerful closing force up to 160 ton
SG60 SG46 Mechanical Grab

Closing Force 160 ton 120 ton Approx. 96 ton (6
Par Wire Rope)
# of Jaw Closing Allowed No limit No limit 1 time / excavation

per Excavation
8.3 Verticality Control

• The most advantageous feature of
Side Flaps
Jintai hydraulic grab over
conventional mechanical grab is
computerized verticality control.
• The grab can be oriented along x and
y-axis, this is essential to achieve a
perfect straight deep wall.
• Operators can observe the
underground condition through
control panel and rectify mistakes at
earlier stage to avoid money loss.
Back Side Flaps
• The maximum of 12 verticality
control flaps can be equipped to our
grab; 4 on front, 4 on back, 2 on left
and 2 on right sides of grab frame.
8.3 Optional Swivel Mechanism

8.4 Components
Componts Brand Country of Origin
Upper Carriage HYUNDAI Korea
Under Carriage Including JINTAI China

Boom
LIFTING Italy
Wire Rope
Engine CUMMINS USA
Control Valves BUCHER Germany
Auxiliary Control Valves REXROTH Germany
Slew Motor REXROTH / Hyundai Germany / Korea
Hydraulic Hose MANULI Italy
PLC EPEC Finland
• Components are subjected to modify subject to engineering design

8.5 Jintai & Bauer Comparison

Technical Comparison JINTAI JINTAI BAUER
SG60 SG46 GB46
Mast Height 18.3m 15.9 m 17.2 m
Center Line of Grab to Swing Center 4100 – 5620mm 4500 – 5360 mm 4000 – 5500 mm
Weight without Grab 92.1 ton  69 ton 68 ton
Single Rope Force 300 kN  230 kN 230 kN
Maximum Hoisting Force 600 kN  460 kN 460 kN
Synchronized Double Main Winches Yes Yes Yes
Maximum Weight of Grab 31.5 ton 23 ton 23 ton
Grab Closing Force 150 ton 120 ton 120 ton
Wall Thickness 0.6 – 1.5 m 0.35 – 1.5 m 0.4 – 1.5 m


SG60 SG46 GB46
Wall Depth 100 m 75 m 75 m
Engine Type Cummins QSM11-C Cummins QSM11-C Caterpillar C7

(SG46E CAT C9)
Engine Power 298 kW @ 1800 263 kW @ 1900 224 kW @ 2200 rpm
rpm rpm
System Pressure 300 bar 300 bar 300 bar
Main Pump Max Flow 2 x 380 L/min  2 x 380 L/min  2 x 225 + 120 L/mim
Crawler Length 6020 mm 5680 mm 5681 mm
Crawler Width 3450 / 4600 mm 3300 – 4400 mm 3270 / 4470 mm
Crawler Shoe Width 800 mm 800 mm 800 mm


SG60 SG46 GB46
Verticality Control Sensor Yes Yes Yes
Flap Control System 4 x Front + 4 x Back 4 x Front + 4 x Back 4 x Front + 4 x Back

Optional: 2 x Left + Optional: 2 x Left + Optional: 2 x Left + 2
2 x Right 2 x Right x Right
Excavation Monitor Yes Yes Yes
Excavation Data Printing Yes Optional Yes Optional
Power Grab Swivel Yes Optional Yes Optional Yes Optional
Wire Rope Type Anti-twist Anti-twist Anti-twist
Hoist Limit Protection Yes Yes Yes

Hope you enjoy our presentation
Thank you for your time!

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Diaphragm Wall Method Statement

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DIAPHRAGM WALL PRESENTATION

• Temporary and / or permanent structures

Major Operations in Diaphragm Wall Construction:

• Guide Wall Installation

1.1 Guide Wall Structure

• 1:3 mortar slab thickness (improve bearing): 70mm

1.1 Guide Wall Structure

• Deviation at center line: +/- 10mm

• Inner wall verticality: < 0.5%

• Excavation width: +/- 10mm

• Top surface flatness: +/- 10mm

• Withstand the construction loads

1.1 Guide Wall Structure

1.2 Guide Wall Extension

1.3 Construction Sequence

• Use excavator for initial

1.3 Construction Sequence

1.3 Construction Sequence

5. Remove Formwork & Add Lateral Support

1.3 Construction Sequence

1.3 Construction Sequence

1.3 Construction Sequence

1.4 Precast Guide Wall

• Used by a Turkish contractor

2.1 Why Needs Drilling Fluid?

• Prevention of wall collapse

2.2 What Is Drilling Fluid?

• The simplest drilling fluid can be prepared by mixing bentonite into

Dispersant (so-called mud thiner)

FCL (Sodium ferrochrome lignin-sulfonate)

Newer Method (Polymer + Water):

2.3 Mechanism of Drilling Fluid

2.4 Relation Between Density and Properties of

2.5 Methods for Adjusting Drilling Fluid

– Add 0.05 - 0.2% CMC

– First to add water to dilute

– Increase bentonite mixing ratio

– Increase bentonite mixing ratio

2.6 Quality of Drilling Fluid

2.7 Case Study of Shenzhen Metro Project

• Drilling fluid specification

2.8 Storage Tank

Storage tank photos:

• Storage tank sizing:

2.8 Drilling Fluid Treatment Equipment

High-speed Automatic Mixer

• Example of 1500 cbm/hr desanding and

2.10 Filter Press

• Portable filter press for U.S.A market

3.1 Excavation Process

• Require 3 bites down to final depth per panel

• Need to flatten the bottom of trench, then clean

Completely Decomposed Rock layer

Hydraulic grab method

Mechanical grab method

• Impact distance: within 1.5m to reduce deviation and vibration

3.2 Collapse Prevention During Excavation

4.1 Typical Panel Arrangement

4.2 Conventional Stop End – Type 1

Conventional Stop End – Type 2

Conventional Stop End – Type 2

5.1 Contact Grout

• Carry out for