Understanding Deep Excavation Formwork
Deep excavation formwork supports the temporary and permanent structures and shapes the excavation site. This support is crucial for the following
-
Preventing Soil Collapse: Using various excavation shoring techniques to prevent soil collapse during digging ensures worker safety and project integrity.
Providing Stability to Vertical Excavations: The retaining wall formwork is a dedicated solution to support the walls of the deep vertical excavations and provide stability.
Tunnel and metro tunnel construction: Tunnel excavation formwork ensures precise alignment and structural support for deep and huge excavations for tunnels and underground metro routes construction.
Waterproofing: The stability of the excavated walls could be compromised by the water ingress. Waterproofing is crucial to protect them. Without robust formwork, deep excavation projects would face significant risks, including structural failures, delays, and increased costs.
Challenges in Deep Excavation Projects
There are several challenges associated with the inherently complex procedure of deep excavation. The construction of basements, underground garages and utility tunnels requires innovative solutions to overcome these initial challenges during excavation:
1. Soil Instability:
Excavating deep into the ground influences the stress distribution within the soil which can destabilise the surroundings.
Advanced reinforcement like excavation shoring techniques can help provide temporary support during the initial digging.
2. Waterproofing: When excavations extend below the water table, groundwater can seep into the excavation site, causing work delays, unstable conditions, and weakening the structure. This water must be controlled through dewatering techniques or should be prevented with cutoff walls to create a dry and stable working environment.
3. Urban Constraints:
Urbanisation has led to densely populated areas. The underground construction in these areas requires deconstructing and reconstructing the grounds. Minimising this disruption to surrounding infrastructure and communities is challenging yet crucial.
4. Railway Proximity:
Deep excavation near active railway lines presents one of the most demanding scenarios in construction. The proximity to rail infrastructure introduces unique risks. Projects near railways must protect tracks from vibrations and structural damage.
To address these challenges, construction teams often rely on prefabricated formwork systems that offer precision, durability, and ease of installation.
Allmarc’s Allwell Deep Foundation: A Game-Changer in Deep Excavation
At Allmarc, we provide Allwell Deep Foundation - a state-of-the-art solution designed to tackle the complexities of large-diameter excavations. This system is engineered to provide unmatched stability, precision, and practicality, making it ideal for urban and railway-adjacent projects.
Key Features of Allwell Deep Foundation
1. Large-Diameter Excavation Support:
Capable of handling diameters ranging from 6 to 11 meters.Utilises robust corrugated steel liner plates to support the bore wall.
2. Superior Soil Stabilisation:
Meticulous grouting between the liner plates and surrounding soil enhances reinforcement and prevents soil collapse.3. Precision Engineering:
Equipped with a top guide frame for accurate alignment and positioning of the formwork.4. Enhanced Practicality:
Features a ladder for easy worker access, a collapsible roof for weather protection, and a reinforcement fixing jig for efficient cage lowering.5. Minimal Disruption:
Designed to protect railway foundations from vibrations and structural issues, ensuring smooth operations in sensitive environments.The Allwell Deep Foundation Process
The manufacturing process of the Allwell Deep Foundation is a testament of Allmarc’s commitment to quality and precision. Here’s a step-by-step overview:
1. Raw Material Inward: Sheets in coil form are received and inspected through the Material Inspection Report (MIR).
2. Forming: The sheets are shaped using a specialised roll-forming machine.
3. Hole Punching: Precisely positioned holes are punched into the formed sheets.
4. Curving: The sheets are curved to diameters ranging from 6 to 11 metres.
5. Gauging: Sensors ensure precise measurements and proper alignment..
6. Cutting: An automated hydraulic shear press cuts the sheets to the required dimensions.
7. Liner Sheet & Curve Beam Formation: End plates and curve beams are shaped to form the final structure.
8. End Plate Welding: Robotic welding ensures precise, strong, and durable end plate attachments.
This meticulous process ensures that every component of the Allwell Deep Foundation meets the highest standards of quality and performance.
Conclusion
Deep excavation projects demand innovative solutions to overcome complex challenges like soil instability, waterproofing, and urban constraints—especially when working near critical infrastructure. At Allmarc, we are committed to delivering reliable and efficient deep foundation solutions. Our Allwell Deep Foundation has been successfully deployed in the Mumbai-Ahmedabad High-Speed Rail (MAHSR) project, ensuring precision, efficiency, and minimal disruption to railway operations. It was a privilege to host stakeholders from NHSRCL, TCAP, and DRA, where we demonstrated how this system integrates advanced design, robust construction, and effective soil stabilisation to support large-diameter excavations.
