Piling Industry Canada, Issue 1, 2023

www.pilingindustrycanada.com

ISSUE 1 • 2023

PIC Piling Industry Canada

magazine

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Eglinton Crosstown: Over and under the existing subway City of Calgary expands Bonnybrook Wastewater Treatment Plant

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In this issue

Published by DEL Communications Inc. Suite 300, 6 Roslyn Road Winnipeg, MB Canada R3L 0G5 www.delcommunications.com

ECA welcomes new team members....................................................................... 6

President & CEO: David Langstaff

Piling Industry Liebherr’s LRH Canada 100.1 unplugged on its first jobsite........................................ 8

Managing Editor: Lyndon McLean lyndon@delcommunications.com

PIC

Eglinton Crosstown: Over and under the existing subway................... 12

magazine

Keller Project Solutions: Chaplin Station in Toronto.................................. 18 City of Calgary expands Bonnybrook Wastewater Treatment Plant to meet the growing needs................................................ 19 Liebherr expands deep foundation applications with LRB 23 and LB 30 unplugged....................................................................... 22 Farrell Design-Build, Inc. acquires the LRB 23 at Conexpo 2023................................................................ 25

Sales Manager: Dayna Oulion dayna@delcommunications.com Advertising Account Executives: Jennifer Hebert Michelle Raike Production services provided by: S.G. Bennett Marketing Services Creative Director / Design: Kathleen Cable © Copyright 2023.

DEL Communications Inc. All rights reserved.The contents of this pub­lica­tion may not be reproduced by any

Hunan Great Steel Pipe Co., Ltd: A leader in steel pipe solutions...............................................................................26

Index to advertisers American Piledriving Equipment..............................................................................................................OBC Arntzen Corporation..........................................................................................................................Belly Band Equipment Corporation of America.......................................................................................................7, IBC

means, in whole or in part, without prior written consent of the publisher.

While every effort has been made to ensure the accuracy of the information contained herein and the reliability of the source, the publisher­in no way guarantees nor warrants the information and is not responsible for errors, omissions or statements made by advertisers. Opinions and recommendations made by contributors or advertisers are not necessarily those of the publisher, its directors, officers or employees.

Fraser River Pile & Dredge (GP) Inc................................................................................................................11 Hercules Machinery Corporation..................................................................................................................13 Interpipe Inc..........................................................................................................................................................10 Junttan Canada Inc.............................................................................................................................................21 Keller.......................................................................................................................................................................... 5 Liebherr Werk Nenzing GMBH........................................................................................................................23 Nucor Skyline...............................................................................................................................................IFC & 3 P1 International Inc............................................................................................................................................15 Samuel Roll Form Group..................................................................................................................................... 9

4 PIC Magazine

Publications mail agreement #40934510 Return undeliverable Canadian addresses to: DEL Communications Inc. Suite 300, 6 Roslyn Road Winnipeg, Manitoba Canada R3L 0G5 Email: david@delcommunications.com PRINTED IN CANADA | 06/2023

PILING Industry News

ECA welcomes

new team members

Jason Church

Earlier this year, ECA Canada Company announced the addition of two key team members in its ongoing effort to serve its customers in eastern Canada and expand into western Canada.

ECA Canada welcomed Account Manager Kevin Sharp, based out of its new Vancouver branch, and BAUER Trainer and After Sales Support Manager Jason Church, out of its Toronto branch.

Sharp comes to ECA Canada with a long history in the foundation drilling industry. His experience as president of Sharp Construction, general manager of Northstar Sharp’s, and as a sales rep with Western Equipment Solutions and Traxxon Foundation Equipment make him a valuable addition to the ECA Canada team in Vancouver.

Sharp said what brought him to ECA Canada was the company’s commitment to training and continuing education. ECA Canada’s focus on bringing strong after sales support to its western Canada customers is another reason for Sharp’s enthusiasm in the role.

“I’m looking forward to being able to provide turnkey solutions for any foundation project for all of our clients,” Sharp said, “No one provides that level of support like ECA.” In his spare time, Sharp is actively involved in junior hockey, even hosting three international junior hockey players full-time at his home.

Church, who was previously the service manager for ECA Canada from 2016-2018, returns to ECA Canada.

With years of experience as a drill rig operator, Church

6 PIC Magazine

Kevin Sharp

comes tailor made for the role, which will see him training rig operators across Canada, supporting the service department at the Toronto branch and managing customer after-sale support.

Church said he’s excited for the opportunity to get back after being away for a few years.

“To be honest, I never wanted to leave,” Church said. “It’s probably the best work environment I’ve ever been in.”

One of Church’s best attributes in his new role at ECA Canada is his passion for teaching and instruction.

“I’ve always liked and felt fulfilled by sharing my experience,” Church said. “Whether it was making mistakes or overcoming challenges. I feel like this is an opportunity to feel this fulfillment all the time. We succeed if our customers succeed.”

ECA has been a leading supplier of foundation construction equipment in the Eastern United States and Eastern Canada for more than a century. We are the exclusive distributor for BAUER Drilling Rigs, KLEMM Anchor and Micropile Drilling Rigs, RTG Piling Rigs, and BAUER MAT Slurry Handling Systems. We also distribute HPSI Vibratory Pile Hammers, WORD International Drill Attachments, Dawson Construction Products, ALLU Ground Improvement Equipment, Pile Master Air Hammers, DIGGA Dangle Drills, Olin Concrete Pumps, and KB International synthetic polymer slurry. ECA offers sales, rentals, service, and parts from nine facilities throughout the Eastern U.S. and Eastern Canadian Provinces. Visit ecanet.com for the latest information on our ever-improving specialty foundation equipment solutions. l

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Piling Industry Canada • June 2023 7

EQUIPMENT Profile

Knock, knock.

Who’s there?

LRH 100.1 unplugged on first jobsite The LRH 100.1 unplugged piling rig is one of the latest models in the electrically driven unplugged series from Liebherr. Fitted with a latest generation hammer H6, it has found its first jobsite in Sweden. Hercules Grundläggning AB is using this model to drive nearly 300 concrete piles into the ground and is very satisfied with the first performance.

“I am retiring in two years. It is very nice to operate such a machine for the last few years.” Mats Andersson operates the piling rig LRH 100.1 unplugged on the jobsite in Karlstad, Sweden and is pleased to “avoid exhaust and noise emissions, and vibrations” with it. It is the first application and endurance test for the battery-powered piling rig from Liebherr.

A building complex with flats, offices and shops on the ground floor is being constructed in Karlstad. In order to transfer the load of the building into load-bearing soil layers, Hercules Grundläggning AB is driving piles into the ground with the LRH 100.1 unplugged.

“We’re installing 284 piles with sizes of 270 by 270 millimetres and lengths between 15 and 20 metres.”

8 PIC Magazine

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EQUIPMENT Profile Flexible for all piling conditions The LRH 100.1 unplugged excels with its large working range. A radius of up to 8.7 metres has the advantage that the

possible to raise or lower the leader

is modular and can be used with

by four metres (e.g., when working in

drop weights of between 3,000 and

a foundation pit), which makes the

6,000 kilogrammes, depending on

machine even more flexible.

requirements. At the jobsite in Karlstad,

machine does not have to be constantly

For the piling work, Hercules

moved. The design of the leader enables

Grundläggning AB has equipped the

inclinations of up to 18 degrees in

LRH 100.1 unplugged with a Liebherr

all directions. Furthermore, it is also

hammer type H6. The hammer

Mats Andersson drives the piles into the soil with a 5,000-kilogramme weight from a drop height of 40 centimetres.

“Here, we are using a free-fall hammer – in other words, it’s not accelerated. We only compensate for the power loss with the cylinders. This has the advantage, especially when driving concrete piles,

ONTARIO 3320 Miles Road, RR#3 that these are not damaged so much as when using accelerated hammers,” Mount Hope, Ontario L0R 1WO explains Liebherr’s Product Manager

erpipe Inc. is a steel pipe distributor of new d used structural steel pipe. We have two ge stocking locations of Seamless, ERW, piralweld and DSAW pipe.

Interpipe Inc. is a steel pipe distributor of new and used structural steel pipe.

We have two andin used structural of steel pipe.thicknesses We have OD – 48” OD a variety wall large stocking locations of of Seamless, ERW, several stocking locations Seamless, e stocked in Spiralweld both locations. and DSAW pipe. pipe.

ERW, Spiralweld and DSAW

3” –48" 48”OD ODininaavariety varietyof ofwall wallthicknesses thicknesses 3" OD OD –min ing Pipe 80,000 yield seamless pipe for are stocked in both locations. are stocked in all three locations. cro Piling.

Piling Piling Pipe Pipe 80,000 80,000 min min yield yield seamless seamless pipe pipe for for Micro Piling.

Micro Piling.

eamless and ERW pipe for Driven Piles, Seamless and pipe for for Driven Driven Piles, Piles, rew Piles and Drill Piles.

Seamless and ERW ERW pipe

Michael Rajek.

Local: (905) 679-6999 ONTARIO ONTARIO 3320 Road, RR#3468-7473 TollMiles Free: (877) 3320 RR#3 Depending on the length of the pile, MountMiles Hope,Road, Ontario Mount Hope, Ontario Fax: L0R 1WO(905) 679-6544 L0R 1WO between 800 and 1,500 strokes of the Local: (905) (905) 679-6999 679-6999 Local: hammer are necessary for each one. In Toll Free: Free: (877) (877) 468-7473 Toll 468-7473 Fax: (905) 679-6544 Fax: (905) 679-6544 QUEBEC

only 10 to 20 minutes, Mats Andersson

805 1 ère Avenue can lift the pile and drive it into the soil.

QUEBEC Ville Ste. Catherine, Quebec QUEBEC 805 1 1 ère ère Avenue Avenue 805 J5C 1C5 “The control system is designed in such a Ville Ste. Catherine, Quebec J5C 1C5

Local: (450) 638-3320 way that the operator can now adjust the

Screw Screw Piles Piles and and Drill Drill Piles.

Piles.

rge DiameterLarge pipe for Driven Caissons.

Diameter pipe for for Pile Drivenor Pile or Large Diameter pipe Driven Piles or Caissons.

Caissons.

Local: (450) 638-3320 pile-driving energy and the number of Toll Free: 514-0040 Toll Free: (888) (888) 514-0040 Fax: (450) 638-3340 Fax: (450) 638-3340 Fax: (450) 638-3340 strokes independently of each other, and

thus ideally adapt to the conditions.”

The hammer used by Hercules belongs to the latest generation in the series.

“We have changed the whole architecture of the existing H6 hammer. The new steel construction is specially designed for stiffness, longevity and for reliability.”

The noise reduction on the jobsite due to the battery-powered piling rig was also continued with the new hammer. “We have a soundproofed pile helmet and pile helmet guide.” Due to the redesign of the

www.interpipe.com 10 PIC Magazine

hammer, the noise emission has been reduced by about 35 per cent.

Performance, safety and zero emission The electro-hydraulic drive of the LRH 100.1 unplugged has the same performance specifications as the conventional version. Both are operated

“T he control system is designed in such a way that the operator can now adjust the pile-driving energy and the number of strokes independently of each other, and thus ideally adapt to the conditions.”

in the same way, which is especially convenient for machine operators if they often must switch between machines.

About the Liebherr Group

The Ground Pressure Visualization

The Liebherr Group is a family-

of the new piling rig calculates the

run technology company with a

current ground pressure in real time and compares it with the specified safety limits of the relevant jobsite. The ground pressure is displayed in the operator’s cabin. This means the operator is permanently aware of whether the machine is situated in, or is approaching, a critical area.

highly diversified product portfolio.

companies across all continents. In 2022, it employed more than 50,000 staff and achieved combined revenues of over 12.5 billion euros. Liebherr was founded in Kirchdorf an der Iller in Southern

The company is one of the largest

Germany in 1949. Since then, the

construction equipment manufacturers

employees have been pursuing the goal

in the world. It also provides high-

of achieving continuous technological

quality and user-oriented products and

innovation and bringing industry-

services in a wide range of other areas.

leading solutions to its customers. l

The Liebherr Group includes over 140

One exceptional feature of the electric drive concept is Zero Emission. The unplugged machines of this series do not produce any exhaust fumes and are

Fraser River Pile & Dredge (GP) Inc.

extremely quiet. This strikes the right note especially in noise-sensitive regions and finds favour with construction site personnel like Mats Andersson.

The battery is charged using a conventional jobsite electric supply.

“That was no problem at all,” Mats Andersson is pleased to say. Operation can continue as normal while charging.

To change to battery operation, you just need to pull out the plug, therefore: unplugged. Whether attached to the electric supply or not, the performance and range of application remains unchanged.

The film shows the first operation of the LRH 100.1 unplugged in Karlstad: Liebherr – LRH 100.1 unplugged in first

As Canada’s largest Marine Construction, Land Foundations and Dredging contractor, FRPD is a recognized leader that employs state of the art methods and equipment. FRPD’s versatile fleet is ready to complete all scope and size Marine Construction, Environmental Remediation, Dredging and Land Foundation projects. Established in 1911 as Fraser River Pile Driving Company and incorporated in 2008 as Fraser River Pile & Dredge (GP) Inc., FRPD’s team of highly skilled professionals brings more than 100 years of experience and commitment to exceeding expectations.

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operation - YouTube Piling Industry Canada • June 2023 11

Eglinton Crosstown:

Over and under the existing subway

By Shawna Munn, P.Eng., Isherwood Geostructural Engineers, and Sarah Speir, P.Eng., Crosslinx Transit Solutions

This article was originally published in DFI’s bi-monthly member magazine, Deep Foundations, January/February 2023 issue. DFI is an international technical association of firms and individuals in the deep foundations and related industries.

To join DFI and receive the magazine, go to www.dfi.org.

12 PIC Magazine

Complex underground work for new light rail tunnels

Cedarvale Station is one of 25 new Eglinton Crosstown light rail transit (ECLRT) stations along Eglinton Avenue in Toronto. It is an interchange station with the existing Toronto Transit Commission (TTC) University subway line and is located at the intersection of two major thoroughfares. The new LRT tunnels run below the existing Yonge Spadina subway line and required total excavation depths of 20 metres (65 feet) to facilitate construction of the new station.

TBM exit and launch shafts The TTC would not allow the tunnel boring machines (TBMs) to tunnel

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The TBM and its carrier crossing Eglinton Avenue.

to traverse Eglinton Avenue without putting additional stress on the existing structure. The entire lift operation took place overnight outside of the existing subway operating hours, over just two nights. It finished ahead of schedule, allowing Eglinton Avenue to be reopened earlier than planned. The overall performance of the support of excavation and TBM bridge during the TBM lift was excellent, with negligible movement detected during real time monitoring of the shaft walls during lifting and lowering of the TBMs, and negligible settlement of the bridge foundations after TBM traverse.

Main station excavation below the existing subway line due to concerns regarding vibration and settlement risk that could cause a disruption in service. Instead, a TBM exit shaft was constructed west of the existing subway line and a TBM launch shaft was constructed east of the subway line, with the future station to be built in between. These shafts formed part of the advance tunnelling contract awarded to Crosstown Transit Constructors (Kenaidan Contracting, Obayashi Canada, Technicore Underground and Kenny Construction Company).

These shafts were constructed by Deep Foundations Contractors (now Green Infrastructure Group [GIP]) based out of Toronto and were designed by Isherwood Geostructural Engineers.

To advance the schedule of the tunnelling operations, it was decided by the tunnelling project team to hoist the still assembled TBM out of the exit shaft via a large gantry crane provided by Mammoet Canada. Due to limited space available to support the gantry crane, the designer and crane provider worked together on a solution to support one side of the gantry crane on the exit and 14 PIC Magazine

launch shaft secant pile walls, adding loads in excess of 2,000 kN (460 kips) to the shoring walls that travel along the wall at the gantry leg location. The TBM was then placed on a specialized hydraulic trailer used to balance ground pressure, to traverse 100 metres (330 feet) along Eglinton Avenue, above ground and the existing subway line, before being lowered via a second gantry assembly into the launch shaft, again supported on the launch shaft secant pile walls.

The existing subway box, located in the middle of the proposed traverse, was constructed in the 1970s and showed signs of corrosion and concrete spalling in the section under Eglinton Avenue. The existing subway structure was also designed under an earlier design code and as a result did not have the spare capacity to support the additional load from the TBM carrier.

To solve this concern, a temporary bridge was constructed to allow the TBM to cross over the subway line, supported on micropile foundations on either side of the existing subway structure. This allowed the TBM carrier

In July 2015, the Eglinton LRT Station contract was awarded to Crosslinx Transit Solutions (EllisDon, Aecon, ACD Dragados Infrastructure Canada and SNC Lavalin). Construction of Cedarvale Station required support of excavation between the exit and launch shafts for the three new station entrances, station platform, concourses, and air shafts, all with varying and sometimes sloping excavation depths ranging from five to 20 metres (16 to 65 feet) depth. To meet the staging needs, various design and construction strategies were employed including temporary staging walls, buried tension struts between adjacent excavations, partial top-down construction to support live traffic and other methods of support around the 28 internal corners were utilized. Support of excavation and traffic deck installation for the main station was constructed by GIP and designed by Isherwood.

The new station is located at an extremely congested location within the city, the intersection of Eglinton Avenue and the junction of the separated highway, William R Allen Road. The new station overlaps and ties into the

Station connection with twin light rail tunnels.

existing Eglinton West Subway and Bus Station, which is serviced by four main bus routes by way of a loop whose entrance and exit are between William R Allen Road South and William R Allen Road North, all of which needed to be maintained throughout construction.

The existing Eglinton West Station also services the Yonge University Spadina subway line, which had to be underpinned to allow for an excavation of 8.5 metres (28 feet) below the existing subway line for the future ECLRT tracks.

The combination of bus and pedestrian traffic from the Eglinton West Station and the vehicular traffic from William R Allen Road made the sequencing of installation of the shoring a significant challenge.

During the construction of Cedarvale Station, traffic flow had to be maintained on Eglinton Avenue, William R Allen Road, and the Eglinton West bus loop as well as all intersections. Approximately 45,000 square feet (4,200 square metres) of steel frame decking with timber mats were constructed and provided a staging area for the construction activities below. The traffic deck was installed in stages. The initial stages were planned to maintain traffic on one side of the road while the shoring, shallow excavation and decking were installed on the other side of the road. These stages had to be further divided when working on the north side of the road due to all the

Working below live traffic on Eglinton Avenue.

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adding any load greater than the existing condition on the structure.

Excavation below the existing subway

Support of excavation for station entrance.

Live traffic over the job site.

intersecting streets that had to remain active (i.e., William R Allen Road North and South and the Eglinton West Station bus loop entrance and exit). This staged installation method necessitated the design and construction of several small temporary supports for the decking and shoring that were later demolished during the excavation.

how to move the heavy construction

Another challenge was the location and depth of the existing subway box. The support of excavation had to be designed around it with a series of perched shoring piles bolted to the top of the TTC box to retain this small height of soil. Challenges arose when determining how to both install these perched piles a top the existing subway box and

dead load on the existing TTC box and

16 PIC Magazine

equipment from one side of the box to the other because the box dissects the middle of the future station and required excavation. A concrete pad was designed and constructed by removing the top one metre (three feet) of soil and replacing it with a lightweight concrete slab that would remove some of the disperse the load of the equipment that would be travelling across the structure and operating on top of the structure without causing damage or undue stress. Once the shoring piles had been installed, the lightweight concrete slab was removed, and the traffic deck was installed spanning over the box to avoid

To support the existing subway line within the excavation so the new ECLRT tracks could pass below, Entuitive, the project’s structural engineer, designed two eight-foot-deep (2.4-metre) plate girders bolted to the side of the existing subway line and spanning across the excavation. Crosslinx brought in Dr. Sauer and Partners, a tunnelling consulting group based out of Salzburg, Austria, to provide the temporary mining support design underneath the subway box that provided structural underpinning support installation. The initial excavation below the subway line took place in six galleries perpendicular to the existing subway boxes. The galleries were designed with shotcrete facing and temporarily supported the subway box above with vertical props.

When a gallery was completed, needle beams were installed through the galleries and connected to the plate girders on either side of the subway line.

The props were then removed. Mining gallery construction was completed by HC Matcon.

During the design phase, it was decided to use the shoring system to support the suspended subway box during the underpinning phase to reduce the number of support caissons required, which would impact the future excavation works and future train testing inside Cedarvale Station. This design change resulted in significant additional load 2,050 kN (460 kips) being carried through the secant pile wall on each side of the existing subway box. The structural plate girders were supported by a recessed connection in the secant pile wall on the south side and structural columns on the north. Jacks

were set up on each needle beam and the plate girders to allow adjustments to accommodate movement of the support system during excavation.

The support of excavation under the subway adjacent to the underpinning mining galleries was particularly challenging because of very limited space for equipment due to the 2.4-metre (eight-foot) mining gallery height and four-metre (13-foot) gallery width, further congested by the underpinning beams supporting the now undermined subway boxes. Any support of excavation in this area also had to account for small allowable movements of the soil supporting the adjacent subway line. The innovative solution to this tricky challenge was to use two stacked 12-metre-long (40-foot) wide-flange waler beam sections installed between the webs of the shoring piles on either side of the subway. The north and south double walers were preloaded toward each other using a series of tie rods, like a bow and arrow, before being encased in reinforced concrete. Once the concrete had reached a minimum design compressive strength, the tensile preload on the tie rods was then released transferring the preload to the reinforced concrete waler beams and soil behind prior to further excavation. This system was designed using the observational method and eliminated the need for cross site bracing in the very tight access and allowed excavation to proceed with enough headroom to install the lower shotcrete wall and four rows of soil anchors. The preloaded waler was monitored throughout preloading, unloading and excavation to ensure it met the design requirements. If movements were to exceed allowable limits, a strut would be installed midspan to limit deflections, optimistically at a late enough construction stage to not impede construction.

Preloading of the walers.

Temporary support of existing subway line.

The overall deflection of the preloaded waler system after final excavation was 12 millimetres (0.5 inches) on the north wall and 0 mm on the south wall, within the 1/1,000 (12 millimetre/0.5 inch) limit imposed by the TTC, and much less than the theoretical non-preloaded deflection of 30 millimetres (1.2 inches).

The overall deflection of the anchored shotcrete shoring system was nine millimetres (0.3 inches), and the existing subway boxes adjacent to the excavation saw less than two millimetres (0.08 inches) differential settlement at the joint locations, within the acceptable range.

Acknowledgments The overall construction of this station spans over a decade and two contracts and involved many companies to

make it a success. Both project teams are responsible for accomplishing this challenging construction saga over and under the existing TTC subway line.

Shawna Munn, P.Eng., is a senior engineer with Isherwood Geostructural Engineers in Mississauga, Ontario. She has more than 12 years of experience in the shoring and specialty foundations field with a focus on complex excavation retention systems and subway infrastructure.

Sarah Speir, P.Eng., is the youngest – and one of the only female – project managers working on the Eglinton LRT project for Crosslinx Transit Solutions.

Before starting on the project in 2015, she got her bachelor’s degree in civil engineering from Queen’s University. l Piling Industry Canada • June 2023 17

PROJECT

Keller Project Solutions: Chaplin Station in Toronto The solution Grouting would stabilize the soil around two drilled shafts without causing excessive movement or soil fracturing.

A cementitious grout mix was injected via multiple port sleeve pipes under high pressure from the underside of the shafts to approximately 9.8 feet (three metres) below the underside of the shaft. A total of 244 cubic feet (6.9 cubic metres) of grout were injected at eight grouting locations with five grouting ports per location.

Keller evaluated grout takes, pressures and movement monitoring to determine if further grouting was required, but the initial preventative grouting program proved successful in stabilizing the shafts

When unexpected movement and

severe sand caving and disturbances.

ground disturbance occurred following

The general contractor proposed a

drilled shaft installation, Keller

preventative grouting program to ensure

Project facts

performed preventative grouting to keep

that the adjacent shafts, critical to project

Owner(s): Metrolinx

the project on track.

completion, were founded on adequate

• Keller business unit(s): Keller

soils with appropriate bearing capacity.

• Main contractor(s): Crosslinx Transit

Chaplin is a new underground station

The challenge

• Engineer(s): Thurber Engineering Ltd.

for the Eglinton Crosstown LRT, part of

The owner set a strict project schedule,

• Solutions: Underpinning

the Toronto subway system. As others

and grouting had to be done within a

• Markets: Infrastructure, Railway

installed drilled shafts, unexpected

tight window to get the project back on

• Techniques: High mobility (cement

soil conditions on one shaft led to

track.

slurry) grouting l

The project

and allowing construction to continue.

Solutions Contractors

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18 PIC Magazine

EQUIPMENT PROJECT Profile

The Bonnybrook Wastewater Treatment Plant upgrades and expansion program

By Paul Adair In spite of its critical importance – especially when you need to flush the toilet or turn on the faucet – wastewater and water treatment is something that isn’t regularly considered. That is, unless you happen to be a city experiencing growth like Calgary.

Sitting on the historic Bow River, Calgary is currently home to three wastewater treatment facilities: Fish Creek, Pine Creek, and Bonnybrook.

Originally built in the 1930s, the largest of the three, the Bonnybrook Wastewater Treatment Plant (WWTP), is one of the largest biological nutrient removal (BNR) plants in Canada, and is the largest cold-weather BNR plant in the world.

But after several significant upgrades and modifications made over the years (the last occurring in the early 1990s) to meet its expanding needs and increasingly stringent treatment standards, it was becoming clear that the plant was nearing its capacity. As such, the City of Calgary made the decision to invest more than $1 billion into the Bonnybrook Wastewater Treatment Plant Upgrades and Expansion Program – a series of extensive upgrades and expansions that will protect the environment and accommodate Calgary’s expected growth well into the future.

Piling Industry Canada • June 2023 19

PROJECT When complete in 2024, the 10year program will expand the plant’s capacity from 950,000 to 1.37 million people, while increasing overall energy efficiency and resiliency.

Plant D expansion By far, the largest component of the

Challenges overcome The ground conditions on site consisted of sands interbedded with deposits of gravel, and the depth to bedrock ranged from four to 14 metres (13 to 46 feet) with groundwater being encountered four metres (13 feet) below working

micropile locations to be redesigned to work around the utilities.

“When a problem like an obstruction was identified, it required quick decisions to be made on the fly,” says Bekkers. “We would coordinate through Graham and with Stantec to

grade.

collaboratively come up with solutions

the Plant D Expansion, which is in of

These ground conditions posed a

itself comprised of several significant

challenge as the new facilities’ stringent

finish the job safely and on time.”

Bonnybrook WWTP program has been

projects. Stantec is the consultant for the program, with Graham Construction as the construction manager.

Stantec’s website states that the Plant D Expansion will include the installation of three additional secondary treatment bioreactors and six additional secondary clarifiers to provide additional secondary treatment

to relocate piles, which allowed us to

settlement criteria required a deep

Flood protection

foundation solution that could support

In 2013, Calgary and the Bonnybrook

the effluent tunnel, installed in a shallow

WWTP were heavily impacted by

excavation underlain with existing active

extensive flooding across southern

utilities. Because of the low-headroom

Alberta, which caused more than $13

and tight space working conditions,

million in damage to the facility. This

the project’s geotechnical engineer

is something the expansion program

recommended the use of micropiles – a

hopes to avoid in the future.

deep foundation element constructed using high-strength, small-diameter

A new 830-metre long (2,720-feet), 3.5-metre (11-feet, 6-inches) high earth

capacity, as well as improvements to

steel casing and/or threaded bars.

primary effluent conveyance, BNR

In 2020, Geotechnical engineering

eastern side of the facility to prevent

company Keller designed, supplied,

overland flows from the river. The

and installed nine micropiles with a

program then relocated several storm

permanent casing up to 14 metres

sewer pipes, removing an existing storm

(46 feet) in length. To ensure the ground

outfall and re-routing trunk sewers. In

processes, secondary clarification, effluent filtration, ultraviolet (UV) disinfection, plant outfall, chemical and process utility systems, secondary sludge thickening, secondary sludge dewatering, thermal hydrolysis of dewatered waste activated sludge, and sludge digestion.

As of 2022, the program has approximately doubled the capacity of the plant’s existing co-generation facility, which captures biogas from the solids treatment process to create electricity and heat for the facility. This upgrade has allowed the Bonnybrook WWTP to seasonally take itself off the grid, further lowering its greenhouse

conditions would not impact the installation, special care had to be taken with the selected drilling method.

“The soil conditions were quite gravelly and cobbly,” says Keller – North America Project Manager Justin Bekkers. “When you drill with air and water in loose sands and gravels, materials can come up the casing and create voids, meaning that we would sometimes have to partially drill the hole, grout it, and then drill it again.”

flood berm was constructed along the

addition, the existing treated effluent outfall has repositioned downstream and embedded into the riverbed to prevent the back-up of river water levels.

The Stantec team then developed a groundwater dewatering system, including a groundwater dewatering pipe, to reduce the impacts of high groundwater levels on existing structures and the site as a whole. These flood mitigation measures will help to ensure that the Bonnybrook WWTP will no longer be affected by rising waters

gas (GHG) emissions and allowing the

Another challenge was related to the

along the Bow River and continue to

plant to reduce its overall operating

abundance of historic infrastructure in

provide uninterrupted services for years

costs.

the area, which necessitated several

to come. l

20 PIC Magazine

EQUIPMENT Profile

Liebherr expands its portfolio for deep foundation applications with new LRB 23 and LB 30 unplugged

The new LRB 23 offers an impressive engine output of 804 hp (600 kW) and so delivers the necessary capacity for all common deep foundation operations, such as Kelly drilling, double rotary drilling, full displacement drilling, continuous flight auger drilling, soil mixing and applications with a vibrator or hydraulic hammer.

The compact design of the LRB 23 allows for transportation in one piece, simplifying mobilization between jobsites and enhancing flexibility. The remote control simplifies the loading process for transportation and assembly of the machine.

22 PIC Magazine

The hammer For impact driving of steel pipes, beams or sheet piles. www.liebherr.com

Deep foundation Hammer H 15 L

EQUIPMENT Profile The advantages of the rigid leader are proven in operation. It can withstand high torques and even Kelly drilling is possible – a unique feature for a machine of this size. The rotary drive BAT 300 delivers a maximum torque of 221,269 lbf-ft (300 kNm).

Highest efficiency and safety through digital assistance systems Locking the Kelly bar’s telescopic sections is made significantly easier with the aid of the Kelly visualization

advantage of zero emissions. The

system in the LRB 23. Thanks to the

drilling rigs can be used for all common

real-time display of the Kelly bar’s

applications in the field of deep

locking recesses on the cab monitor, the

foundation.

operator is constantly informed about the actual distance to the next locking recess. Colour indications also inform the operator when the bar can be locked.

Furthermore, false positioning of the Kelly bar during the shake-off process is indicated through a warning signal.

During continuous flight auger drilling, the concreting process is automated thanks to the drilling assistant. All assistance systems contribute to time savings, higher availability of the

Thanks to the optional extension of the drilling axis, the machines can be deployed for drilling diameters of up to 11.2 feet (3.4 metres). The optional rear support and the new design of the modular rear counterweight ensure

About Liebherr USA, Co. Liebherr USA, Co., based in Newport News, VA, provides sales and service on behalf of 10 different Liebherr product segments: earthmoving, material handling, mining, mobile and crawler cranes, tower cranes, concrete technology, deep foundation machines, maritime cranes; components, and refrigeration and freezing.

higher stability and longer service life.

About the Liebherr Group

In addition to the standard design, both

The Liebherr Group is a family-run

machines are available in a Low Head version with a total height of 46.3 feet (14.1 metres), or as Ultra Low Head with

technology company with a highly diversified product portfolio. The company is one of the world’s largest manufacturers of construction

machine and a significant increase in

only 25.5 feet (7.7 metres).

safety during operation. The newly

For battery operation, the charging

user-oriented products and services in

cable only needs to be unplugged and,

multiple other areas. Today, the group

for unlimited operation, reconnected to

consists of more than 140 companies

the construction site power supply. The

across all continents. In 2021, it

battery is designed for a working time of

employed more than 49,000 people and

four hours in Kelly operation. Whether

achieved combined revenues of over

designed piling and drilling rig offers precision, high performance, and a long service life.

LB 30 unplugged Over many years, the drilling rigs LB 25 and LB 30 have proven themselves in the conventional version. The new battery-operated unplugged versions

in battery or plugged-in operation, the drilling performance remains unchanged.

machinery. It also offers high-quality,

11.6 billion euros. Liebherr was founded in 1949 in Kirchdorf an der Iller in southern Germany. Ever since then, the company’s employees have been

are identical regarding application

Insights of the LRB 23 in operation can

committed to satisfying customers with

possibilities, weight, or transport;

be viewed at Liebherr - The all-rounder:

advanced solutions and to helping drive

however, they have the additional

LRB 23 - YouTube.

technological progress. l

24 PIC Magazine

PILING CanadaIndustry News

Farrell Design-Build, Inc. acquires the LRB 23 piling and drilling rig at Conexpo 2023 California based, Farrell Design-Build, Inc. acquires a Liebherr LRB 23 piling and drilling rig at Conexpo 2023 to be used in various applications.

Left to Right: Sascha Bechter, Martin Walser, Bertrand Meiss, Steven Whisenhunt, Kyle Wallace, Andrew Carter, James Patterson, Bruno Marchand, and Thomas Soria.

Specializing in proven, design-build, ground improvement

The company intends to use this machine to preform:

support and deep foundation pile solutions, Farrell Design-

• Auger Cast Pile & Drill Displacement Pile

Build, Inc. purchases a Liebherr LRB 23 at Conexpo 2023.

The California-based deep foundation systems and services company will initially use the LRB 23 for full displacement soil improvement. Farrell Design-Build, Inc. also provides design-

• Auger Cast Column & Drill Displacement Column • Compacted Aggregate Pier & Compacted Soil Column • Vibro Stone Column & Vibro Displacement Column

build excavation support solutions, foundation design peer

• Rapid Impact Compaction & Rapid Vibro Compaction

review, and specialty ground improvement and pile design

• Drill Pipe Piles, Micro Piles & Helical Piles

services.

The LRB 23 is a compact piling and drilling rig that closes

Farrell Design-Build, Inc. chose the LRB 23 due to its high

the gap between the LRB 16 and the long-proven LRB 355.

horsepower, ease of transport, and versatility of use.

The impressive engine output provides the machine with the

“This is the best machine for vibrated stone columns and full

such as Kelly drilling, double rotary drilling, full displacement

necessary capacity for all common deep foundation work,

displacement drilling,” Tom Farrell, MS-CE-GE, President and

equipment and continuous flight auger, as well as soil mixing

CEO of Farrell, notes.

and applications with a vibrator or hydraulic hammer. l

“This is the best machine for vibrated stone columns and full displacement drilling,” Tom Farrell, MS-CE-GE, President and CEO of Farrell, notes.

Piling Industry Canada • June 2023 25

PILING Industry News

Hunan Great Steel Pipe Co., Ltd:

A leader in steel pipe solutions

Hunan Great Steel Pipe Co., Ltd, founded in 1993, has emerged as a leading supplier of steel pipes, fittings, helical piles, and welding spools.

Additionally, the company offers comprehensive pipe fabrication services.

Committed to excellence, their products adhere to API, EN, BS, DIN, and JIS standards, ensuring top-tier quality that meets the diverse demands of their clients.

With a remarkable total production capacity of 200,000 metric tons per year and an expansive workshop spanning 560,000 square meters, Hunan Great Steel Pipe Co. is equipped to handle even the most ambitious projects. Their vast warehouse consistently stocks over 1,000 metric tons per month, featuring a wide range of materials and sizes to accommodate various requirements.

Engaging in over 100 projects annually, their products find applications in vital industries such as oil & gas pipelines, 26 PIC Magazine

drilling, offshore operations, energy, shipbuilding, power stations, and petrochemical and construction sectors.

This extensive reach underscores their commitment to serving the everevolving needs of these industries.

enables them to efficiently cater to the

In the dynamic North America market, Hunan Great Steel Pipe Co. stands strong with the support of their trusted agents, P1 International Inc. Their partnership serves as a testament to the company’s commitment to delivering exceptional steel pipe solutions in the region. Mrs. Claire Chang, a representative from Hunan Great Steel Pipe Co., expressed admiration for the remarkable professionalism and unwavering dedication demonstrated by P1 International Inc.

Pipe Co. stems from their consistent

With a shared vision and a deep understanding of the industry, P1 International Inc. seamlessly aligns with the strategic objectives of Hunan Great Steel Pipe Co. Their collaboration

diverse needs of their customers and provide tailored solutions that exceed expectations.

The reputation of P1 International Inc. as a trusted agent for Hunan Great Steel delivery of excellence. By upholding the highest standards of professionalism, they ensure a seamless experience for clients and reinforce the reputation of both companies.

As Hunan Great Steel Pipe Co. continues to revolutionize the steel pipe industry with their top-notch products and unwavering commitment, they solidify their position as pioneers in delivering comprehensive and reliable steel pipe solutions.

For more information about Hunan Great Steel Pipe Co. and their extensive product offerings, visit their website at www.hunantube.com. l

Sales | Rentals | Parts & Service | Training

Empowering our customers to safely operate the most advanced equipment in the industry to its fullest capabilities is a no-brainer.

J OE KI NWORT HY, ECA D I R ECT OR OF T R A I NI NG

At ECA, we place a premium on giving our people the space to innovate when they see a need. Joe saw the long-term value in developing a certified training program with the aim of producing the industry’s best operators and technicians. Our focus on continuous education, exploration, and collaborative problem-solving translates to innovative solutions that add to our customers’ bottom lines. Together, we are moving the industry forward.

Let us help build your legacy one successful project at a time.

ecanet.com/piling-industry-ca 1 800 PILE USA

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