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User Manual: TITAN 8 Passive

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A new dimension for ground engineering from

JIBO: Injection Boring

JDynamic pressure grouted, cas-

ing free one step installation

JSuits all ground conditions

JRapid, effective ground and

structural stabilization (ground

improvement)

CON-TECH SYSTEMS Ltd.

Devised by Ernst Ischebeck in 1983,

Ischebeck Titan's ground engineering

solutions provide engineers in the con-

struction and civil engineering indus-

tries with a new dimension in structural

and geotechnical reinforcement, reten-

tion and stabilization techniques.

CTS/TITAN IBO (Injection BOre)

ground engineering solutions utilize a

hollow steel bar, which has a continu-

ous thread running along its external

wall. A suitable drill bit is fitted to the

end of the bar to penetrate the struc-

ture or material requiring stabilization

and a drill rig is used to install the bar

into the desired position. Grout is

injected through the hollow bar and

ejected from apertures in the drill bit.

Pressure then forces the grout back

along the outside of the bar to form a

strong, monolithic stabilizing structure.

CTS/TITAN IBO ground engineering

techniques provide solutions for

anchor, soil nail, pile, rock bolt or

ground improvement applications, with

a wide variety of bar sizes, drill bits and

accessories available to suit every

requirement.

The versatility of the CTS/TITAN IBO

solution is evident in the number and

variety of projects on which it has been

used, often providing a more econom-

ic, efficient and effective alternative to

traditional construction and engineer-

ing methods.

This brochure details the principles and

techniques employed in CTS/TITAN

IBO ground engineering solutions.

Separate literature is available covering

the various anchor, soil nail,micro pile

and rock bolt applications.

Expert technical advice on product

selection and scheme design is always

available from Con-Tech System’s qual-

ified engineers.

Production benefits

• Single step casing free operation

significantly improves productivity

• Suitable for difficult and restricted

access situations

• Ability to use smaller drilling rigs

reduces mobilization costs

Geotechnical benefits

• Extremely low settlement character-

istics - less than 5 mm at working

load

• Enhanced mechanical bond with

surrounding ground (ground

improvement)

• Minimal disturbance during installa-

tion

Material benefits

• No requirement for double corro-

sion protection in permanent works

• On site fabrication provides design

flexibility

• Wide variety of drill bits to suit differ-

ent ground conditions.

CTS/TITAN IBO (Injection Bore) System

CTS/TITAN IBO System

Spherical

collar nut

Wedge

discs

Washer

plate

Sheet pile

wall

Annulus

stabilised

Coupling

nut

Centraliser

Hollow

threaded

bar

Grout cover

> 20mm

Grout body

Drill bit

Spherical

collar nut

Wire

mesh

Shotcrete

Washer

plate

Annulus

stabilised

Coupling

nut

Centraliser

Hollow

threaded

bar

Grout cover

> 20mm

Grout body

Drill bit

Coupling

nut

Centraliser

Grout body

Drill bit

Concrete pile

head

Bore hole

ø130mm

Grout

body

Coupling

nut

Drill bit

De-bond

tube

(if required)

Hollow

threaded

bar Hollow

threaded

bar

Eye

bolt

Rock

netting

Anchor Soil Nail Pile Rock Bolt

The Ischebeck Titan solution uses the

hollow threaded bar as a conduit for

either air, water or grout flushing medi-

ums. The medium used is dependent

on the ground conditions encountered.

For example: Rock would normally

require air or water whereas soft or col-

lapsing ground would require grout.

Grout Flushing

The density of the grout is varied

depending on the ground conditions;

the greater the need to support the

annulus, the thicker the grout required.

Typically a W/C ratio of between 0.7

and 0.4 would be used.

The flushing head transmits the rotary

and percussive forces from the drilling

machine to the drill bit, whilst allowing

continuous pumping of the flushing

medium through the hollow Titan bar.

The flushing medium leaves the aper-

tures of the drill bit under pressure, cre-

ating a continuous low pressure scour-

ing action against the sides of the drill

hole. This action exposes the harder

parts of the hole whilst flushing and

removing the softer parts to the sur-

face.

When each bar has been drilled to

depth, it is withdrawn back up the mast

and then redrilled in a reaming action

to improve cuttings return and increase

the scouring of the grout flush.

Scouring creates a very rough, irregu-

lar shaped grout body with a much

greater mechanical connection to the

soil, providing greater pull-out resist-

ance and lower settlement characteris-

tics.

Installation

Active zone

Passive zone

Irregular grout body

Hand held drill rigs

Limited drill bit diameter and limited

installed length, depending on ground

conditions.

Titan bar diameter

30/16

30/14

30/11

Drilling equipment

TEI Rock Drill

Hand rotary percussion

Crawler mounted drill rigs

Open access

Restricted access

Excavator mounted

Masts

Titan bar diameter

30/16 40/20

30/14 40/16

30/11 52/26

Drilling equipment

Ingersol Rand LM 400

TEI Rock Drill

Morath HGB110

Boart Fleximaster HD160

Pneumatic/hydraulic rotary percussive

male shank - R32, R38, T38, T45, R55

Installation Equipment

Installation equipment

The result of using good equipment

Open access

Titan bar diameter

40/20

40/16

52/26

73/53

103/78

103/51

130/60

Drilling equipment

Klemm 802, 803

Krupp HB 40a, HB60a

Cassagrande C6, C9

TEI Rock Drill

Hydraulic rotary percussive heads

2500Nm torque min., male shank -

R55, C64, H55, H112

Grout consumption approx 20 kg/m

Ordinary Portland cement dependent

on drill bit size and ground conditions.

Titan bar diameter for 20kg/m

30/16

30/14

30/11

Grouting equipment

Injection technique requires:- Grout

station capable of mixing and pumping

at the same time; Colloidal mixer and

an agitating storage tank with capacity

of 240 litre; Moyno, piston or plunger

pump of approx 35l/min, such as

Obermann plunger pumps.

Installation & Grouting Equipment

Grouting equipment

Grout consumption approx. 40 kg/m

Ordinary Portland cement dependent

on drill bit size and ground conditions.

Titan bar diameter for 40kg/m

40/20

40/16

52/26

73/53

103/78

103/51

130/60

Grouting equipment

As above but higher capacity of

100l/min at up to 100 bar,

such as Obermann VS100, VS110

Large crawler mounted

drill rigs

Service life

Ischebeck Titan injection ground engi-

neering products provide a service life in

excess of 120 years based on research

which has been accepted by both, the

UK Railway and Highways Agencies.

This research is detailed below.

Steel Characteristics

The steel utilized within the ground engi-

neering products is a high quality, micro

alloy structural steel with relatively high

yield and tensile capacity. It has similar

properties in terms of corrosion to that

used for both sheet piles and reinforce-

ment bars. It is vert ductile.

This high yield steel has a low carbon

content and as a result is not susceptible

to stress corrosion cracking or hydrogen

embrittlement.

Sacrificial Steel allowance

The UK Highways Agency Design

Manual for Roads and Bridges incorpo-

rates section HA68/94 - Design Methods

for the Reinforcement of Highway Slopes

by Reinforced Soil and Soil Nailing

Techniques.

Appendix C of this document is entitled

Corrosion of Metallic Reinforcement and

Soil Nails, and refers to Transport

Research Laboratory Research Report

380 (1993) - The Development of

Specifications for Soil Nailing; R T

Murray TRL RR380 sets out the parame-

ters by which soil can be categorized for

ground aggressivity, with ranking values

from non-aggressive to highly aggres-

sive.

The report produces the expected loss

of sacrificial thickness of metal over

elapsed time. In Table 1 opposite, this

data has been applied to the cross sec-

tional area of Ischebeck Titan bar sizes

to give an expected loss of steel strength

over 60 and 120 year periods. This only

applies to the steel buried in the ground

with no other protective measures taken.

Section 4.3 of TRL RR380 suggests that

“the grout surrounding the nail could be

regarded as enhancing the soil environ-

ment so that the requirements for sacrifi-

cial allowances may be reduced. One

strategy, for example, would be to

regard the soil as falling within the adja-

cent lower category of aggressiveness”.

In the USA the Utah Department of

Transportation and the Federal Highway

Administration (FHWA) approved the use

of the sacrificial steel method for a soil

nail retaining wall in the Provo Canyon.

Sacrificial Steel Allowance

Sacrificial Steel Loss Technical Data

Cement grout

Hydrated cement provides an alkaline

environment in the region of pH 12.6 -

13. When steel is encased within such

an environment, chemical as well as

physical corrosion protection is provid-

ed. This is due to the fact that a steel

surface remains electrically passivated

by the alkali environment, resisting car-

bonation, which would allow aggres-

sive anions to ingress and attack the

steel (see also “Extreme corrosive con-

ditions” below).

The adjacent diagram illustrates why

cement grout within this pH value pro-

vides an active corrosion protection.

Crack width limitation

Unlike rope threads, the Ischebeck

Titan thread is coarse, widely spaced

and has a groove taken out of the

crown. This induces controlled crack-

ing of the grout along the length of the

bar.

Corrosion is likely to occur initially

where the bar intersects a crack.

Therefore, the smaller the crack width

the lower the risk of corrosion. British

Standard guidelines propose that crack

widths of <0.1mm are acceptable in a

cementitious protective barrier.

Shear friction tests, in conjunction with

crack width measurements, have been

carried out on the Titan thread. The

results have shown that the frequency

of cracking within a grout body can be

controlled to such an extent that the

crack widths stay well below the per-

mitted 0.1mm.

Identical tests have also been carried

out using hollow rope threaded bars.

However, the crack width was over

0.2mm above the permitted 0.1mm

and, therefore, the grout cannot be

considered as an acceptable cementi-

tious protective barrier.

This has been determined by extensive

testing and research carried out by the

LGA Geotechnical Institute, University

of Munich.

Corrosion Protection

Extreme corrosive

conditions

To qualify for class I corrosion

protection (as per PTI recom-

mendations) in extreme corro-

sive conditions, TITAN bars

can be manufactured out of

“INOX” steel (see page 14).

They can also be protected by

epoxy coating, metallizing or

combi-coating.

LGA Test 1997

Summary of test 1250/MU/2800/523 dt 29/07/97

Crack Width Limitation

Subject of test: Titan 30/11 within an excavated OPC grout body

Purpose of test: To determine the number and dimension of the cracks in the grout body dur-

ing stressing of the anchor tendon to 125% of its SWL.

Result of test: Cracks, which were not visible to the human eye, were induced along the

entire length of the grout body. Every crack measured less than 0.10mm.

Explanation: The drilling and flushing method used causes scouring of the drill hole. The

softer parts of the drill hole are flushed out and the harder parts are exposed.

Final pressure grouting creates the strongest possible mechanical connection

at the grout/ground interface. The unique thread on the Titan anchor bar has

a groove on the crown which is designed to encourage the backflow of cut-

tings and flushing fluid during drilling. The roughness of this thread produces

the strongest possible mechanical connection at the grout/tendon interface.

Scientific examination of the grout body revealed that the spacing of the hair-

line cracks corresponded with the spacing of the threads on the Titan anchor

bar.

Conclusion: At the SWL of 150kN and with all cracking limited to less than 0.10mm the

grout body provides complete corrosion protection.

Our commitment to providing you with

the optimum in ground engineering

solutions is illustrated by our invest-

ment in independent research pro-

grams, which enable us to develop and

refine the performance and quality of

our products for a wide variety of

ground conditions.

Excavated grout bodies of a Titan

micro pile, soil nail or anchor confirm:

• Grout body has enhanced diameter

• Irregular grout body generates

extremely high soil friction

• Continuous and homogeneous

grout cover without contamination

• Ground improvement

Research & Development

Key features

1. Utilization of a steel hollow

bar as the tendon From the stat-

ic point of view, a hollow bar is

superior to a solid rod of the same

cross sectional area with respect to

bending moment, shear resistance

and surface bond/friction.

2. Titan hollow bar is manufac-

tured from high yield micro

alloy high quality structural

steel offering high notch tough-

ness > 39J. This steel is not affect-

ed by hydrogen embrittlement or by

stress crack corrosion.

3. The threads on Titan hollow

bar are formed much like the

ribs on a reinforcing bar fab-

ricated according to DIN 488

& ASTM-A 615. The deep Titan

threads result in 2.4 times higher

bond friction compared to standard

drill steel coil-threads of R 32 (1¼”)

or R 38 (1½”)

4. Continuous threads guaran-

tee the Titan bar can be cut

or coupled anywhere along its

length. Cutting, extending, pre-

stressing and load releasing on the

tendon are possible. A thread pitch

of 6° eliminates the need for locking

nuts at each coupling.

Product Specifications

Product specifications

Ischebeck Titan hollow bar type denotes external diameter of bar followed by its internal diameter. For

example, a Titan 30/16 bar has an external diameter of 30mm and an internal diameter of 16mm.

The ultimate load at yield (or the corresponding load which occurs at a constant elongation of 0.2%)

was tested by MPA, (the material testing institute of the state of Northrhine Westfalia,

Dortmund/Germany). This also applies to the cross sections. Above figures are valid for INOX anchors

as well. The stresses mentioned were calculated from the load and cross section values of MPA

Hollow bar

Sizes:

A comprehensive selection of

Ischebeck Titan hollow bar is available

in sizes 30/16 to 130/60 and with ulti-

mate capacity of 220kN to 7900kN.

See product specifications and table

on page 13 for details.

Finishes:

Black: This high quality, low carbon

content, high yield hollow steel bar is

suitable for the majority of applications

where normal environmental conditions

are present.

Epoxy Coated, Metallized or

Galvanized: Additional protection for

aggressive conditions; used in con-

junction with correspondingly coated

accessories. For class I corrosion pro-

tection.

Inox (a stainless steel): A feritic-

austenitic steel

(inox duplex),

material no.

1.4462. Used for

extremely aggres-

sive environ-

ments.

Accessories

Ischebeck Titan offers a wide variety of

accessories to complement the entire

hollow bar range, providing the flexibili-

ty to install the bar in different ground

conditions with different drilling equip-

ment to suit different applications. The

comprehensive range of accessories

includes coupling nuts, centralizing

spacers, washer plates, adaptor bits,

wedge discs, collar nuts and many

more ancillary items.

Drill bits

System Components

Soft soil

Hardened clay drill bit 75mm to 280mm

Medium rock

Button drill bit 42mm to 70mm

Cross cut drill bit 90mm to 175mm

Hard rock

Carbide button drill bit 90mm to 180mm

Carbide cross cut bit 46mm to 70mm

Flushing heads

Various types are available to suit dif-

ferent bar sizes and drilling rigs:-

S22 - Handheld rock drill with a hexag-

onal female shank

R32/R38/T38/T45 - Pneumatic rotary

percussive drilling rig

R55 - Hydraulic hammer drilling rigs

Soil Nails - Slope Stabilization Provo

Canyon

- Slope stabilization repair after con-

ventionally nailed wall failed

- CTS/TITAN 40/16 permanent soil

nails

- Corrosion protection through grout

body

- Sacrificial steel allowance, use

approved by UDOT and FHWA

- Owner: UDOT

Contractor: Obayashi

Tie-Backs - Harbor Green Shoring

Vancouver

- Excavation Shoring

- CTS/TITAN 30/16 & 40/20

- Temporary anchors

- Corrosion protection through grout

body

- Owner: ASPAC Developments

Contractor: Southwest Contracting

Tie-Backs - Slide Stabilization in

Ocean Side near San Diego

- Stabilization of residential area

- CTS/TITAN 40/20

- Owner: Home Owner Association

Contractor: Condon Johnson

Micro Piles - Louisville

- Foundations for power house

- Low headroom

- Karst ground

- CTS/TITAN 103/78 micro piles

- Corrosion protection through grout

body

- Owner: Kentucky Power

Contractor: Morris Shea Bridge Co.

Feature Projects

Con-Tech Systems Ltd.

Head Office and Western Division

8150 River Road

Delta, BC V4G 1B5, Canada

Toll Free: 1-888-818 4826

Fax: 604 946-5548

California USA

Tel: 619 659-9931

Fax: 619 659-9932

Cell: 619 894-2616

Plants: Delta, BC, Blaine, WA &

Bakersfield, CA

Eastern Division

4502 Hanna Drive

Elizabethtown, ON K6T 1A9 Canada

Tel: (613) 342-0041

Fax: (613) 342-0609

Florida USA

Toll Free: 1-866-848-6800

Cell: (727) 224-0143

Plants: Brockville, ON

Contact

CON-TECH SYSTEMS Ltd.

T-Wall Repair, CTS/TITAN 103 Micropiles

Contractor: Hayward Baker; Owner: CALTRANS

Ver: 0501

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