A new dimension for ground engineering from

IBO: Injection Boring

Dynamic pressure grouted, cas-ing free one step installation

Suits all ground conditions

Rapid, effective ground andstructural stabilization (groundimprovement)

CON-TECH S Y S T E M S L t d .

Devised by Ernst Ischebeck in 1983,Ischebeck Titan's ground engineeringsolutions provide engineers in the con-struction and civil engineering indus-tries with a new dimension in structuraland geotechnical reinforcement, reten-tion and stabilization techniques.

CTS/TITAN IBO (Injection BOre)ground engineering solutions utilize ahollow steel bar, which has a continu-ous thread running along its externalwall. A suitable drill bit is fitted to theend of the bar to penetrate the struc-ture or material requiring stabilizationand a drill rig is used to install the barinto the desired position. Grout isinjected through the hollow bar andejected from apertures in the drill bit.Pressure then forces the grout backalong the outside of the bar to form astrong, monolithic stabilizing structure.

CTS/TITAN IBO ground engineeringtechniques provide solutions foranchor, soil nail, pile, rock bolt orground improvement applications, witha wide variety of bar sizes, drill bits andaccessories available to suit everyrequirement.

The versatility of the CTS/TITAN IBOsolution is evident in the number andvariety of projects on which it has beenused, often providing a more econom-ic, efficient and effective alternative totraditional construction and engineer-ing methods.

This brochure details the principles andtechniques employed in CTS/TITANIBO ground engineering solutions.Separate literature is available coveringthe various anchor, soil nail,micro pileand rock bolt applications.

Expert technical advice on productselection and scheme design is alwaysavailable from Con-Tech System’s qual-ified engineers.

Production benefits

• Single step casing free operationsignificantly improves productivity

• Suitable for difficult and restrictedaccess situations

• Ability to use smaller drilling rigsreduces mobilization costs

Geotechnical benefits

• Extremely low settlement character-istics - less than 5 mm at workingload

• Enhanced mechanical bond withsurrounding ground (groundimprovement)

• Minimal disturbance during installa-tion

Material benefits

• No requirement for double corro-sion protection in permanent works

• On site fabrication provides designflexibility

• Wide variety of drill bits to suit differ-ent ground conditions.

CTS/TITAN IBO (Injection Bore) System

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CTS/TITAN IBO System

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Sphericalcollar nut

Wedgediscs

Washerplate

Sheet pilewall

Annulusstabilised

Couplingnut

Centraliser

Hollowthreadedbar

Grout cover> 20mm

Grout body

Drill bit

Sphericalcollar nut

Wiremesh

Shotcrete

Washerplate

Annulusstabilised

Couplingnut

Centraliser

Hollowthreadedbar

Grout cover> 20mm

Grout body

Drill bit

Couplingnut

Centraliser

Grout body

Drill bit

Concrete pilehead

Bore holeø130mm

Groutbody

Couplingnut

Drill bit

De-bondtube(if required)

Hollowthreadedbar

Hollowthreadedbar

Eyebolt

Rocknetting

Anchor Soil Nail Pile Rock Bolt

The Ischebeck Titan solution uses thehollow threaded bar as a conduit foreither air, water or grout flushing medi-ums. The medium used is dependenton the ground conditions encountered.For example: Rock would normallyrequire air or water whereas soft or col-lapsing ground would require grout.

Grout FlushingThe density of the grout is varieddepending on the ground conditions;the greater the need to support theannulus, the thicker the grout required.Typically a W/C ratio of between 0.7and 0.4 would be used.

The flushing head transmits the rotaryand percussive forces from the drillingmachine to the drill bit, whilst allowingcontinuous pumping of the flushingmedium 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 drillhole. This action exposes the harderparts of the hole whilst flushing andremoving the softer parts to the sur-face.

When each bar has been drilled todepth, it is withdrawn back up the mastand then redrilled in a reaming actionto improve cuttings return and increasethe scouring of the grout flush.

Scouring creates a very rough, irregu-lar shaped grout body with a muchgreater mechanical connection to thesoil, providing greater pull-out resist-ance and lower settlement characteris-tics.

Installation

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Installation

5

Active zone

Passive zone

Irregular grout body

Hand held drill rigsLimited drill bit diameter and limitedinstalled length, depending on groundconditions.

Titan bar diameter

30/1630/1430/11

Drilling equipment

TEI Rock DrillHand rotary percussion

Crawler mounted drill rigsOpen accessRestricted accessExcavator mountedMasts

Titan bar diameter

30/16 40/2030/14 40/1630/11 52/26

Drilling equipment

Ingersol Rand LM 400TEI Rock DrillMorath HGB110Boart Fleximaster HD160Pneumatic/hydraulic rotary percussivemale shank - R32, R38, T38, T45, R55

Installation Equipment

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Installation equipment

The result of using good equipment

Open access

Titan bar diameter

40/2040/1652/2673/53103/78103/51130/60

Drilling equipment

Klemm 802, 803Krupp HB 40a, HB60aCassagrande C6, C9TEI Rock DrillHydraulic rotary percussive heads2500Nm torque min., male shank -R55, C64, H55, H112

Grout consumption approx 20 kg/mOrdinary Portland cement dependenton drill bit size and ground conditions.

Titan bar diameter for 20kg/m

30/16 30/1430/11

Grouting equipment

Injection technique requires:- Groutstation capable of mixing and pumpingat the same time; Colloidal mixer andan agitating storage tank with capacityof 240 litre; Moyno, piston or plungerpump of approx 35l/min, such asObermann plunger pumps.

Installation & Grouting Equipment

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Grouting equipment

Grout consumption approx. 40 kg/mOrdinary Portland cement dependenton drill bit size and ground conditions.

Titan bar diameter for 40kg/m

40/2040/1652/2673/53103/78103/51130/60

Grouting equipment

As above but higher capacity of100l/min at up to 100 bar,such as Obermann VS100, VS110

Large crawler mounteddrill rigs

Service lifeIschebeck Titan injection ground engi-neering products provide a service life inexcess of 120 years based on researchwhich has been accepted by both, theUK Railway and Highways Agencies.This research is detailed below.

Steel CharacteristicsThe steel utilized within the ground engi-neering products is a high quality, microalloy structural steel with relatively highyield and tensile capacity. It has similarproperties in terms of corrosion to thatused for both sheet piles and reinforce-ment bars. It is vert ductile.

This high yield steel has a low carboncontent and as a result is not susceptibleto stress corrosion cracking or hydrogenembrittlement.

Sacrificial Steel allowanceThe UK Highways Agency DesignManual for Roads and Bridges incorpo-rates section HA68/94 - Design Methodsfor the Reinforcement of Highway Slopesby Reinforced Soil and Soil NailingTechniques.

Appendix C of this document is entitledCorrosion of Metallic Reinforcement andSoil Nails, and refers to TransportResearch Laboratory Research Report380 (1993) - The Development ofSpecifications for Soil Nailing; R TMurray TRL RR380 sets out the parame-ters by which soil can be categorized for

ground aggressivity, with ranking valuesfrom non-aggressive to highly aggres-sive.

The report produces the expected lossof sacrificial thickness of metal overelapsed time. In Table 1 opposite, thisdata has been applied to the cross sec-tional area of Ischebeck Titan bar sizesto give an expected loss of steel strengthover 60 and 120 year periods. This onlyapplies to the steel buried in the groundwith no other protective measures taken.

Section 4.3 of TRL RR380 suggests that“the grout surrounding the nail could beregarded as enhancing the soil environ-ment so that the requirements for sacrifi-cial allowances may be reduced. Onestrategy, for example, would be toregard the soil as falling within the adja-cent lower category of aggressiveness”.

In the USA the Utah Department ofTransportation and the Federal HighwayAdministration (FHWA) approved the useof the sacrificial steel method for a soilnail retaining wall in the Provo Canyon.

Sacrificial Steel Allowance

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Sacrificial Steel Loss Technical Data

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Cement groutHydrated cement provides an alkalineenvironment in the region of pH 12.6 -13. When steel is encased within suchan environment, chemical as well asphysical corrosion protection is provid-ed. This is due to the fact that a steelsurface remains electrically passivatedby the alkali environment, resisting car-bonation, which would allow aggres-sive anions to ingress and attack thesteel (see also “Extreme corrosive con-ditions” below).

The adjacent diagram illustrates whycement grout within this pH value pro-vides an active corrosion protection.

Crack width limitationUnlike rope threads, the IschebeckTitan thread is coarse, widely spacedand has a groove taken out of thecrown. This induces controlled crack-ing of the grout along the length of thebar.

Corrosion is likely to occur initiallywhere the bar intersects a crack.Therefore, the smaller the crack widththe lower the risk of corrosion. BritishStandard guidelines propose that crackwidths of <0.1mm are acceptable in acementitious protective barrier.

Shear friction tests, in conjunction withcrack width measurements, have beencarried out on the Titan thread. Theresults have shown that the frequencyof cracking within a grout body can becontrolled to such an extent that thecrack widths stay well below the per-mitted 0.1mm.

Identical tests have also been carriedout using hollow rope threaded bars.However, the crack width was over0.2mm above the permitted 0.1mmand, therefore, the grout cannot beconsidered as an acceptable cementi-tious protective barrier.

This has been determined by extensivetesting and research carried out by theLGA Geotechnical Institute, Universityof Munich.

Corrosion Protection

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Extreme corrosiveconditions

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

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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 theentire 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. Thesofter parts of the drill hole are flushed out and the harder parts are exposed.Final pressure grouting creates the strongest possible mechanical connectionat the grout/ground interface. The unique thread on the Titan anchor bar hasa groove on the crown which is designed to encourage the backflow of cut-tings and flushing fluid during drilling. The roughness of this thread producesthe 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 anchorbar.

Conclusion: At the SWL of 150kN and with all cracking limited to less than 0.10mm thegrout body provides complete corrosion protection.

Our commitment to providing you withthe optimum in ground engineeringsolutions is illustrated by our invest-ment in independent research pro-grams, which enable us to develop andrefine the performance and quality ofour products for a wide variety ofground conditions.

Excavated grout bodies of a Titanmicro 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

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Research & Development

Key features

1. Utilization of a steel hollowbar as the tendon From the stat-ic point of view, a hollow bar issuperior to a solid rod of the samecross sectional area with respect tobending moment, shear resistanceand surface bond/friction.

2. Titan hollow bar is manufac-tured from high yield microalloy high quality structuralsteel offering high notch tough-ness > 39J. This steel is not affect-ed by hydrogen embrittlement or bystress crack corrosion.

3. The threads on Titan hollowbar are formed much like theribs on a reinforcing bar fab-ricated according to DIN 488& ASTM-A 615. The deep Titanthreads result in 2.4 times higherbond friction compared to standarddrill steel coil-threads of R 32 (1¼”)or R 38 (1½”)

4. Continuous threads guaran-tee the Titan bar can be cutor coupled anywhere along itslength. Cutting, extending, pre-stressing and load releasing on thetendon are possible. A thread pitchof 6° eliminates the need for lockingnuts at each coupling.

Product Specifications

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Product specifications

Ischebeck Titan hollow bar type denotes external diameter of bar followed by its internal diameter. Forexample, 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 anchorsas well. The stresses mentioned were calculated from the load and cross section values of MPA

Hollow bar

Sizes:A comprehensive selection ofIschebeck Titan hollow bar is availablein sizes 30/16 to 130/60 and with ulti-mate capacity of 220kN to 7900kN.See product specifications and tableon page 13 for details.

Finishes:Black: This high quality, low carboncontent, high yield hollow steel bar issuitable for the majority of applicationswhere normal environmental conditionsare present.

Epoxy Coated, Metallized orGalvanized: Additional protection foraggressive conditions; used in con-junction with correspondingly coatedaccessories. For class I corrosion pro-tection.

Inox (a stainless steel): A feritic-austenitic steel(inox duplex),material no.1.4462. Used forextremely aggres-sive environ-ments.

Accessories

Ischebeck Titan offers a wide variety ofaccessories to complement the entirehollow bar range, providing the flexibili-ty to install the bar in different groundconditions with different drilling equip-ment to suit different applications. Thecomprehensive range of accessoriesincludes coupling nuts, centralizingspacers, washer plates, adaptor bits,wedge discs, collar nuts and manymore ancillary items.

Drill bits

System Components

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Soft soilHardened clay drill bit 75mm to 280mm

Medium rockButton drill bit 42mm to 70mmCross cut drill bit 90mm to 175mm

Hard rockCarbide button drill bit 90mm to 180mmCarbide 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 shankR32/R38/T38/T45 - Pneumatic rotarypercussive drilling rigR55 - Hydraulic hammer drilling rigs

Soil Nails - Slope Stabilization ProvoCanyon

- Slope stabilization repair after con-ventionally nailed wall failed

- CTS/TITAN 40/16 permanent soilnails

- Corrosion protection through groutbody

- Sacrificial steel allowance, useapproved by UDOT and FHWA

- Owner: UDOTContractor: Obayashi

Tie-Backs - Harbor Green ShoringVancouver

- 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 inOcean 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

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Con-Tech Systems Ltd.

Head Office and Western Division

8150 River RoadDelta, BC V4G 1B5, CanadaToll Free: 1-888-818 4826Fax: 604 946-5548

California USATel: 619 659-9931Fax: 619 659-9932Cell: 619 894-2616

Plants: Delta, BC, Blaine, WA &Bakersfield, CA

Eastern Division

4502 Hanna DriveElizabethtown, ON K6T 1A9 CanadaTel: (613) 342-0041Fax: (613) 342-0609

Florida USAToll Free: 1-866-848-6800Cell: (727) 224-0143

Plants: Brockville, ON

Contact

CON-TECH S Y S T E M S L t d .

T-Wall Repair, CTS/TITAN 103 MicropilesContractor: Hayward Baker; Owner: CALTRANS

Ver: 0501