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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
EFFC – Annual Meeting – Berlin 2015Geosynthetics in Special FoundationsDipl.-Ing. Hartmut Hangen – HUESKER Synthetic GmbH
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Agenda
08.01.2016 2
HUESKER SYNTHETIC
Geosynthetics Basic Knowledge
Access Roads
Working Platforms
Piled Embankment
Geotextile Encased Columns
Fabric Containment
Dewatering of Sludge
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
HUESKER Synthetic
08.01.2016 3
Where tradition meets progress…
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
History
08.01.2016 4
1861 Founded as H.&J. Huesker & Co.
1863Start of cotton fabric production in the newly built facilities.
1958 Merging of various production locations for spinning, weaving and finishing in Gescherand surrounding areas.
1913 Production on 1172 looms with 613 employees
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
History
08.01.2016 5
1971Launch HaTelit®
1972Launch Stabilenka®
1987Launch Fortrac®.
1973Foundation of independentHUESKER Synthetic GmbH
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
History
08.01.2016 6
2006 Launch SoilTain®
2015Opening of productionin Dülmen
1991Foundation of subsidiaryHUESKER Inc. (USA)
1991Launch productLubratec®
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UnternehmenspräsentationEFFC – anual meeting – Berlin 201508.01.2016 7
H Inc. / Charlotte
Huesker Ltda / São José dos Campos
Huesker S.A.S. / Gresswiller
Huesker Asia / Singapur
NaBento Vliesstoffe / EllefeldHuesker S.r.l./ Triest
HUESKER Group
Headquarter
Sales partner
Subsidiary
HUESKER Inc. / Charlotte
HUESKER Ltda. / São José dos Campos
HUESKER Ltd. / WarringtonNaBento Vliesstoff GmbH / Ellefeld
HUESKER France SAS / Gresswiller
HUESKER geosintéticos S.A. / Noain
HUESKER S.r.l. / Triest
HUESKER Synthetic GmbH / Gescher
HUESKER OOO / Moscow
HUESKER Middle East / Jordan
HUESKER Asia / Singapore
HUESKER Synthetic B.V. / Den Dungen
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Production facilities
08.01.2016 8
Gescher (Germany)Gescher (Germany)
Dülmen (Germany)Dülmen (Germany)
Ellefeld (Germany)Ellefeld (Germany)
Shelby (USA)Shelby (USA)
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Business Areas
08.01.2016 9
Roads andPavements
Earthworks andFoundations
Environmental Engineering
HydraulicEngineering
Mining Industrial Agriculture
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Earthworks and Foundations - Applications
1
Embankments on Piles
Embankments on Soft Soils
Bridging of Sinkholes
Geosynthetic ReinforcedSoil
Geotextile EncasedColumns
08.01.2016 10
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Roads and Pavements - Applications
08.01.2016 11
Temporary Roads Railways Permanent Roads
Working Platforms andWind Turbines
Rehabilitation ofConcrete Pavements
Rehabilitation of Asphalt Pavements
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Hydraulic Engineering
08.01.2016 12
Dams and Dikes
Revetments
Bed / Sour Protection
Breakwaters
Bank Protection
Canals
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Environmental Engineering
08.01.2016 13
Landfill Construction
Groundwater Protection
Water Reservoir
Sludge LagoonRemediation
Dewatering
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Agriculture
08.01.2016 14
Biogas and Manure
Cover Systems
Textil Halls
Light and Air
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Product Groups (GEO)
08.01.2016 15
Grids Container Wovens
Nonwovens GCL Composites
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Agenda
08.01.2016 16
HUESKER SYNTHETIC
Geosynthetics Basic Knowledge
Access Roads
Working Platforms
Piled Embankment
Geotextile Encased Columns
Fabric Containment
Dewatering of Sludge
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UnternehmenspräsentationEFFC – anual meeting – Berlin 201508.01.2016
Basic knowledge about Geosynthetics
17
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Geosynthetics / product groups
geogrids
woven geogrids
knitted geogrids
drawn geogrids
stirps
special products
permeable impermeable / low permeability
geocomposites
geomembranes
geomembranes
geos. clay liners(GCL)
geotextiles
non-woven
woven
knitted
1808.01.2016
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Functions of Geosynthetics
191908.01.2016
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Polymer properties
Technical data of most typical raw materials for GSY production
Raw material PA (6,6) PE PET PP AR PVA
Density (g/m3) ~ 1,14 ~ 0,95 ~ 1,36 ~ 0,90 ~ 1,44 ~ 1,31Soft. / MeltingTemperature (°C) ~ 220 / 260 ~ 105 / 135 ~ 230 / 260 ~ 150 / 165
carbonized> 450 ~ 220 / 260
Specific strength High Medium High Medium Excellent HighUltimate strain ofyarn (%) 30 - 50 15 - 30 9 - 15 10 - 20 3 - 4 5 – 6
Creep Low High Low High Low LowResistance:- acid- alcaline- light (UV)
badgoodbad
goodgoodbad
goodbad
good
goodvery good
bad
goodgoodlow
goodvery good
good08.01.2016 20
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Production / Nonwoven
08.01.2016 21
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Production / geogrid punched and drawn
08.01.2016 22
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Production / woven geogrid
08.01.2016 23
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Reinforcement / ultimate vs. design strength
The design tensile strength of a geosynthetic reinforcement is calculated applying partial reduction factors on the ultimate tensile strength of the virgin product. Those reduction factors are product specific
RB,k0 /
(RFcreep x RFinst x RFconn x RFenv x RFdyn x M)
– RB,k0 = Ultimate Tensile Strength as per CE-Datasheet
– RB,d = Design Strength / - resistance2408.01.2016
RB,d =
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Reinforcement / ultimate vs. design strength
RFcreep : creep ruptureRFinst : installation damageRFconn : connectionsRFenv : environmental influencesRFdyn : dynamic loadingM : partial material factor
2408.01.2016
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Deh
nung
Zeit
Kra
ft
time
time
Polymers and Creep
Testing of creep characteristics
Ref.: Hufenus
08.01.2016 26
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Creep rupture
00,5
11,5
22,5
33,5
44,5
5
AR PVA PET PA PEHD PP
RED
UR
CTI
ON
FAC
TOR
R
F cr
eep
[-]
Bruch 10% Ref: Thornton, Lothspeich, EuroGeo 2000, Bologna
08.01.2016 27
break
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Rfinst., Rfconnec., Rfenvironm.
08.01.2016 28
RFconn ~ 2,0
Ainstall ~ 1,05..1,40
Aenv ~ 1,00...1,03
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Geosynthetics and special foundations
Current and potential applications
08.01.2016 29
Access roads and working platformsvalidation of global stability of embankments in connection with ground improvementPiled embankment raft foundationDesign and execution of geotextile encased columnsTemporary formwork preventing excess consumption of concreteReduction of negative skin frictionDewatering of sludge or containment of sludge
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Agenda
08.01.2016 30
HUESKER SYNTHETIC
Geosynthetics Basic Knowledge
Access Roads
Working Platforms
Piled Embankment
Geotextile Encased Columns
Fabric Containment
Dewatering of Sludge
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UnternehmenspräsentationEFFC – anual meeting – Berlin 201508.01.2016
Access Roads
31
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Base reinforcement
Parameters to consider
Geosynthetic:
biaxial vs. uniaxialstrain vs. strengthinstallation damageinterlocking
reinforcing
filtration
separation
drainage
08.01.2016 32
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Base reinforcement
Further parameters… reinforcement
filtration
separation
drainageconsolidation / pore water
pressure
compaction / granular material
loading
…
08.01.2016 33
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Base reinforcementMechanisme and relevant parameters
Tensile stiffnessInteraction soil / reinforcementInterlockingOpening sizeWater permeabilityRobustness
Load distribution
Membran action
Separation / filtration08.01.2016 34
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Base reinforcementThe required base-course thickness can be estimated using empiric design data
08.01.2016 35
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Agenda
08.01.2016 36
HUESKER SYNTHETIC
Geosynthetics Basic Knowledge
Access Roads
Working Platforms
Piled Embankment
Geotextile Encased Columns
Fabric Containment
Dewatering of Sludge
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UnternehmenspräsentationEFFC – anual meeting – Berlin 201508.01.2016
Working Platforms
37
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Working platforms
Typical Loading and arrangement for load distribution
08.01.2016 38
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Working platforms
Current design approaches
08.01.2016 39
BR 470EBGEO : 2010
SVG
DIN EN 791:2010-01MeyerhoffGiroudKleih…
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Working platform
Support us in research!
08.01.2016 40
Prof. Moormann (Stuttgart University)
To answer questions like:
non linear stress distributionDynamic ladingModel „two layer soil system“Include reinforcement
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Agenda
08.01.2016 41
HUESKER SYNTHETIC
Geosynthetics Basic Knowledge
Access Roads
Working Platforms
Piled Embankment
Geotextile Encased Columns
Fabric Containment
Dewatering of Sludge
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UnternehmenspräsentationEFFC – anual meeting – Berlin 201508.01.2016
Piled Embankemnt
42
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Piled embankment with basal reinforcement
08.01.2016 43
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Piled embankment
Design procedure (EBGEO, CUR)
08.01.2016 44
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Piled embankment
Market
08.01.2016 45
Design guidance availableAccepted solution from clients like e.g. German Railway (DB-Netz AG)
Future challanges:Optimize No. of vertical bearing members // strength of reinforcementOptimize design and execution processFind design methode for triangular pattern of vertical bearings
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Agenda
08.01.2016 46
HUESKER SYNTHETIC
Geosynthetics Basic Knowledge
Access Roads
Working Platforms
Piled Embankment
Geotextile Encased Columns
Fabric Containment
Dewatering of Sludge
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UnternehmenspräsentationEFFC – anual meeting – Berlin 201508.01.2016
Geotextile Encased Columns
47
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Alternative foundation system
Geotextile encased columns – Ringtrac®
08.01.2016 48
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Geotextile encased columns
characteristics
08.01.2016 49
Suitable for very soft soils (su < 15 kPa)
Fast construction of high embankments with no danger of bearing failure
System is highly adaptable to local conditions and loads
Reduced settlements and accelerated consolidation
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Installation techniques
Displacement
08.01.2016 50
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Installation techniques
Replacement
08.01.2016 51
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Installation techniques
Vibro float
08.01.2016 52
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Agenda
08.01.2016 53
HUESKER SYNTHETIC
Geosynthetics Basic Knowledge
Access Roads
Working Platforms
Piled Embankment
Geotextile Encased Columns
Fabric Containment
Dewatering of Sludge
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UnternehmenspräsentationEFFC – anual meeting – Berlin 201508.01.2016
Fabric Containment
54
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Fabric containment for soil anchors or piles
Motivation
08.01.2016 55
Limit loss of cement mortar during grouting or anchors / piles in karsticsoils / fractured rockPrevent hydraulic colaps during grouting of anchors / piles in soft soils
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Fabric containment for soil anchors and piles
08.01.2016 56
Ref. : Spesa
Concept
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Fabric containment for soil anchors and piles
Rock anchors
08.01.2016 57
Ref. : Haka Gerodur
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Fabric containment for soil anchors and piles
Containment forbored piles
08.01.2016 58
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Fabric containment for soil anchors and piles
Typical requirements for containment
08.01.2016 59
Max. diameter during installation: 100 mm… 180 mmTo be defined / customized:
Max expected. filling pressure under working conditionsDesired permeability of fabricExpansion ratio
Required strength Raw material Opening size Confection diameter Required length
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Incomat®Standard
-sealing-protection-Constant thickness
Incomat®Flex
- erosion protection- filter points
-Rough surface
Incomat®Crib
- vegetative erosion protection
Incomat®Filterpunkt
- erosion protection- many filterpoints
Incomat® - double layer fabric mattress
08.01.2016 60
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Incomat® - double layer fabric mattress
Incomat mattress
fabric
fabric
spacer
08.01.2016 61
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Incomat® - double layer fabric mattress
Incomat standard for sealing or protection
08.01.2016 62
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Incomat®
Alternativ applications
Pipe protection and uplift protectionBallast and protection of geomembranes
08.01.2016 63
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Incomat®
Pipe protection
08.01.2016 64
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Agenda
08.01.2016 65
HUESKER SYNTHETIC
Geosynthetics Basic Knowledge
Access Roads
Working Platforms
Piled Embankment
Geotextile Encased Columns
Fabric Containment
Dewatering of Sludge
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UnternehmenspräsentationEFFC – anual meeting – Berlin 201508.01.2016
Dewatering of Sludge
66
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
System configuration
08.01.2016 67
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
SoilTain Tube Dewatering
Features
Optimization of application through resource-efficient tube sizesRecirculation of water, e.g. as process waterSludge encapsulation prevents rewettingVery high filling capacityLow energy requirementStraightforward installation
08.01.2016 68
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Application example
Key data
100,000 m3 in-situ sludge volume345,000 m3 dredged volumeSuction dredger with a capacity of 10,000 m3/day
08.01.2016 69
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
System comparison on capacity
08.01.2016 70
Dredger operation: 10 h/day
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Time comparison for complete dewatering
08.01.2016
7108.01.2016
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Maschine employment
08.01.2016 72
Chamber filterpress
Belt filterpress
Centrifuge
30
20
10
Number ofmachines
22
30
12
Number of machines required to match SoilTaindewatering speed
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Cost comparison
Relevant costs
Labout costsConstruction site staff for the whole dewatering process
Asset costsMaschines (Lease or Buy)Tubes
Operating costsMaintenanceConsumables (Energy, Polymers etc.)
08.01.2016 73
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Cost comparison
08.01.2016 74
Costs (in Mio. €) for 100,000 m³ in situ sludge
3,8 3,5 2,8 2,4 1,9
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Performance comparison
08.01.2016 75
++ Very good + Good • Neutral - Poor -- Very poor
SystemFactor
Water quality • -- • • •
Low maintenance intensity ++ ++ -- - --
VR/DS + - ++ + ++
Mobility ++ -- • • •
Capacity ++ ++ -- - -
Low investment + ++ - - -
SoilTain Dredge dump Chamber filter press Belt filter press Centrifuge
Permanent storage ++ ++ -- --
Low space requirement • -- ++ ++ ++
--
Low energy consumption ++ ++ - - --
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
High-flow dewatering
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Summary - Geotextiles in special foundations
08.01.2016 77
Geosynthetics product groups Geosynthetics offer potential for new application areas
Base reinforcement: a fewrelevant paramters to consider
Stress distribution and high strengthfor working platforms
Piled Embankment: accepted slutionsand a few market challenges
Geotextile encased columns asan alternative foundation system
Double layer fabric mattres for soilanchors, piles and pipe protection
Dewatering of sludge with thehigh performance system SoliTain®
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015
Summary - Geotextiles in special foundations
08.01.2016 78
HUESKER offers reliable high quality products
Wide range of technologies and raw-materials
Partner for development and project phase
Excellent network
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UnternehmenspräsentationEFFC – anual meeting – Berlin 2015