Ground improvements underway near Bayfair roundabout
Significant ground improvement works are underway inside and around the Bayfair roundabout with the installation of lattice piling framework. These works are a key milestone for the Bay Link project to progress the new underpass and construction of the SH2 flyover bridge.
Ground strengthening work is a major part of the project, given the nature of sandy soils, sub-surface material and the high-water table in the area. Around 5600 stone columns have already been installed throughout the site to help densify the ground, limiting any potential liquefaction during an earthquake.
The original plan for ground densification under the flyover bridge over the Maunganui-Girven intersection included stone columns.
In late 2019, following the installation of stone columns, testing indicated a variable layer of pumice was present which did not respond as anticipated to stone column ground improvements. Additional investigations by the universities of Auckland and Canterbury, and an international expert, confirmed the unusual behaviour and complexity of this layer and concluded a revised design methodology was required.
The modified approach to ground improvements around Bayfair is a lattice piling framework that will help limit settlement and provide further stability. This approach involves constructing a network of overlapping concrete columns, arranged in a square lattice. The primary piles are augured, concrete pumped through the auger and the auger slowly extracted, replacing displaced ground with concrete. At completion of the primary piles, secondary piles are installed which overlap the two adjacent piles, creating a sealed wall.
To install the lattice piles, two giant drilling rigs are located on-site for around six months while the works are underway. Weighing approximately 72 tonnes each and up to 25 metres high, the first rig is located next to the former underpass and the second rig is located within the Bayfair roundabout.
The lattice piles are being installed around each of the five supports for the flyover bridge. As part of the ground improvements work, the Bayfair roundabout has been enlarged to accommodate construction.
Undertaking the works and operating the rigs safely in such a confined area presents some logistical challenges, including working closely with Tauranga Airport to ensure the height of the rigs’ masts don’t intrude on the flight path. Working alongside live traffic lanes also means the safety of motorists, members of the public and road workers is paramount.
As part of the works, it’s estimated that 9000m3 concrete will be poured (equalling more than 21,600 tonne). This will be delivered by around 1800 truck movements.
It’s anticipated the lattice piling works will mainly occur during the day. While the Bay Link project team endeavours to minimise any disturbance to local residents, the ground improvements work may generate some noise and vibration.
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